CN101034609A - Amorphous soft magnetic alloy and inductance component using the same - Google Patents
Amorphous soft magnetic alloy and inductance component using the same Download PDFInfo
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Images
Abstract
To provide an amorphous soft magnetic alloy having a supercooled liquid region and excellent in amorphous-forming ability and soft magnetic properties, by selecting and optimizing an alloy composition, and to further provide a ribbon, a powder, a high-frequency magnetic core, and a bulk member each using such an amorphous soft magnetic alloy. The amorphous soft magnetic alloy has a composition expressed by a formula of (Fe1-alphaTMalpha)100-w-x-y-zPwBxLySiz, wherein unavoidable impurities are contained, TM is at least one selected from Co and Ni, L is at least one selected from the group consisting of Al, V, Cr, Y, Zr, Mo, Nb, Ta, and W, 0<=alpha0.98, 2<=w<=16 at %, 2<=x<=16 at %, 0<y<=10 at %, and 0<=z<=8 at %).
Description
Technical field
The present invention relates to a kind of amorphous soft magnetic, also relate to the web, band, powder, element and the parts that use this alloy in addition.
Background technology
Amorphous magnetic alloy rises prior to Fe-P-C, develops low-loss material Fe-Si-B, high saturation magnetic flux metric density (Bs) material Fe-B-C etc. afterwards.These materials are because loss is low is supposed to as transformer material, but because its cost is high and with to compare its Bs such as the conventional material of silicon steel sheet lower, so also be not used widely.In addition, because these amorphous alloys requirement cooling rates are 10
5K/sec or higher only is the band of about 200 μ m (laboratory highest level) so can only produce thickness.Therefore, must be wound into described band in the magnetic core or with described tape lamination in magnetic core, this has greatly limited the application of amorphous alloy.
Since the latter half 1980s, begun to develop the alloy system of so-called metal glass, in this alloy system, with at that time before amorphous alloy opposite, observe glass transition and the supercooled liquid scope occurred at the low temperature side of crystallization temperature.The supercooled liquid scope is considered to be related to the stability of glass structure.Therefore, it is very good that the noncrystalline of this alloy system forms ability, and this never occurred before at that time.For example, have been found that Ln-Al-TM, Zr-Al-Ni, and have been found that Pd-Cu-Ni-P base alloy, therefrom can make the metal glass block element of about several millimeters thick respectively.Since middle 1990s, also found the Fe base metal glass, and reported and to have realized that thickness is the composition of 1mm or above metal glass block element.For example, found Fe-(Al, Ga)-(P, C, B, Si) (non-patent literature 1:Mater.Trans., JIM, 36 (1995), 1180), Fe-(Co, Ni)-(Zr, Hf, Nb)-B (non-patent literature 2:Mater.Trans., JIM, 38 (1997), 359; Patent documentation 1: Japanese unexamined patent open (JP-A) No.2000-204452), Fe-(Cr, Mo)-and Ga-P-C-B (patent documentation 2: Japanese unexamined patent open (JP-A) No.2001-316782), Fe-Co-RE-B (patent documentation 3: Japanese unexamined patent open (JP-A) No.2002-105607) etc.Yet, with the alloy phase ratio of routine,, these alloys form ability although all having improved noncrystalline separately, and exist owing to containing a large amount of non magnetic one-tenth and grade and make the problem that saturation flux density is low.Be difficult to make that noncrystalline formation ability and magnetic property are all satisfactory.
Usually known amorphous alloy such as Fe-Si-B and Fe-P-C, is known high magnetic permeability and low-loss material, therefore is suitable for transformer core, magnetic head etc.Yet because that noncrystalline forms ability is low, thickness is the band of about 20 μ m and wire rod that thickness is about 100 μ m only becomes commercialized, and they also should be formed magnetic core lamination or that twine in addition.Therefore, the degree of freedom of vpg connection is minimum.On the other hand, make dust core by the low-loss noncrystalline powder that will have good soft magnet performance and can realize three-dimensionally shapedly, therefore this be regarded as very hopeful.Yet, because it is not enough to form ability according to any described composition noncrystalline, so be difficult to adopt water atomization method or similar approach to make powder.In addition, if use the iron-nickel alloy material or the similar material of the cheapness that contains impurity, expection reduces noncrystalline and forms ability so, thereby reduces amorphous consistency, therefore causes weakening of soft magnet performance.With regard to the Fe base metal glass, all very strong although their noncrystalline separately forms ability equally, because they contain a large amount of nonmetal compositions, and the content of iron series element is very low, so be difficult to satisfy simultaneously the requirement of its magnetic property.In addition, because glass transition temperature is higher, the problem that heat treatment temperature etc. raises can appear equally also.
Summary of the invention
Therefore the objective of the invention is to, propose a kind of amorphous soft magnetic, by alloy composition being selected and being optimized, can make it have the supercooled liquid scope, and noncrystalline formation ability is very high, soft magnet performance is also fine.
Another object of the present invention is, proposes all to use band, powder, high frequency magnetic core, the block elements of this amorphous soft magnetic.
In order to realize aforementioned purpose, after process is carried out lucubrate to various alloy composites, the present inventor finds, join in the Fe-P-B base alloy and by one or more elements that will from Al, V, Cr, Y, Zr, Mo, Nb, Ta and W, choose and to determine those composition component, can realize improving noncrystalline and form ability and tangible supercooled liquid scope occurs, and finish the present invention.
In addition, the present inventor finds, join in the Fe-P-B base alloy and in addition Ti, C, Mn and Cu element are joined in the Fe-P-B base alloy and by one or more elements that will from Al, Cr, Mo and Nb, choose and determine those composition component, can realize improving noncrystalline forms ability and tangible supercooled liquid scope occurs, this has further improved alloy composite, and has finished the present invention.
According to an aspect of the present invention, provide a kind of amorphous soft magnetic, the expression formula of its composition is (Fe
1-αTM
α)
100-w-x-y-zP
wB
xL
ySi
zWherein contain unavoidable impurities, TM is choose from Co and Ni at least a, L is choose from the group that is made of Al, V, Cr, Y, Zr, Mo, Nb, Ta and W at least a, 0≤α≤0.98,2 atom %≤w≤16 atom %, 2 atom %≤x≤16 atom %, 0 atom %＜y≤10 atom %, 0 atom %≤z≤8 atom %.
According to a further aspect in the invention, provide a kind of amorphous soft magnetic, the expression formula of its composition is (Fe
1-αTM
α)
100-w-x-y-zP
wB
xL
ySi
zTi
pC
qMn
rCu
sWherein contain unavoidable impurities, TM is choose from Co and Ni at least a, L is choose from the group that is made of Al, Cr, Zr, Mo and Nb at least a, 0≤α≤0.3,2 atom %≤w≤18 atom %, 2 atom %≤x≤5 atom %, 0 atom %＜y≤10 atom %, 0 atom %≤z≤4 atom %, wherein all to be illustrated in the gross mass of Fe, TM, P, B, L and Si be 100 o'clock interpolation ratio for each p, q, r and s, and be defined as 0≤p≤0.3,0≤q≤0.5,0≤r≤2,0≤s≤1.
According to another aspect of the invention, provide a kind of amorphous soft magnetic element of making by above-mentioned amorphous soft magnetic.The thickness of described amorphous soft magnetic element is 0.5mm or thicker, and cross-sectional area is 0.15mm
2Or it is bigger.
In accordance with a further aspect of the present invention, provide a kind of amorphous soft magnetic band of making by above-mentioned noncrystalline soft magnetism.The thickness of described amorphous soft magnetic band is 1 to 200 μ m.
According to another aspect of the invention, provide a kind of amorphous soft magnetic powder of making by above-mentioned amorphous soft magnetic.Described amorphous soft magnetic particles of powder size is 200 μ m or following (except zero).
In accordance with a further aspect of the present invention, provide a kind of by described amorphous soft magnetic element is processed the magnetic core that forms.
According to another aspect of the invention, provide a kind of and twine the magnetic core that forms by above-mentioned amorphous soft magnetic band being carried out annular.
According to a further aspect in the invention, provide a kind of and described amorphous soft magnetic band is carried out the above-mentioned magnetic core that the annular winding forms by insulator.
In accordance with a further aspect of the present invention, provide a kind of and carry out the stacked magnetic core that forms by sheet spare or part to the basic identical shape of above-mentioned amorphous soft magnetic band.
According to a further aspect in the invention, provide a kind of by to comprising above-mentioned amorphous soft magnetic powder and carrying out the molded magnetic core that forms with the mixture that 10 quality % or amount still less add this material powder of stating the adhesive in the amorphous soft magnetic powder.
According to another aspect of the invention, provide a kind of inductance component that forms on the above-mentioned magnetic core that is applied in by the coil that will have at least one circle.
In accordance with a further aspect of the present invention, provide a kind of by above-mentioned magnetic core and coil are carried out the Unitarily molded inductance component that forms.In described inductance component, described coil forms by twining at least one astragal shape conductor, and is placed in the described magnetic core.
According to a further aspect in the invention, a kind of inductance component is provided, the coil that this inductance component will have at least one circle is applied on the magnetic core and forms, described magnetic core is by to comprising above-mentioned amorphous soft magnetic powder and carry out molded formation with the mixture that 5 quality % or amount still less add the material powder of the adhesive in this amorphous soft magnetic powder, the activity coefficient of the described material powder in described magnetic core be 50% or more than.In described inductance component, Q (1/tan δ) peak value of described inductance component in 10kHz or above frequency band be 20 or more than, Q (1/tan δ) peak value of described inductance component in 100kHz or above frequency band be 25 or more than, Q (1/tan δ) peak value of described inductance component in 500kHz or above frequency band be 40 or more than, Q (1/tan δ) peak value of perhaps described inductance component in 1MHz or above frequency band be 50 or more than.
By Fe amorphous alloy composition of the present invention is selected, can obtain having supercooled liquid scope and noncrystalline and form very high, the good alloy of soft magnet performance of ability.
In addition, according to the present invention, can make the band, powder, high frequency magnetic core and the block elements that use noncrystalline to form the very high and good this amorphous soft magnetic of soft magnet performance of ability.
Description of drawings
Fig. 1 is the exterior perspective view according to an example of the basic structure of high frequency magnetic core of the present invention;
Fig. 2 is for by being wrapped in coil the exterior perspective view of the inductance component that forms on the high frequency magnetic core shown in Figure 1;
Fig. 3 is the exterior perspective view according to another example of the basic structure of high frequency magnetic core of the present invention;
Fig. 4 is for by being wrapped in coil the exterior perspective view of the inductance component that forms on the high frequency magnetic core shown in Figure 3;
Fig. 5 is the exterior perspective view according to the another example of the basic structure of high frequency magnetic core of the present invention;
Fig. 6 is the Fe with different-thickness
78P
8B
10Mo
4The XRD result curve figure that band obtains according to X-ray diffraction (XRD) method; With
Fig. 7 is the Fe with varying particle size
78P
8B
10Mo
4The result curve figure that powder obtains according to X-ray diffraction (XRD) method.
Embodiment
Below the present invention is elaborated.
At first, the first basic composition of amorphous soft magnetic of the present invention is set forth.
The present inventor is (Fe through many-sided discovering when passing through to select the composition expression formula to determine alloy composite
1-αTM
α)
100-w-x-y-zP
wB
xL
ySi
zThe time, can obtain the amorphous soft magnetic powder that excellent magnetic and noncrystalline form the high economy of ability, wherein contain unavoidable impurities, 0≤α≤0.98 wherein, 2 atom %≤w≤16 atom %, 2 atom %≤x≤16 atom %, 0 atom %＜y≤10 atom %, 0 atom %≤z≤8 atom %, Fe, P, B and Si represent iron respectively, phosphorus, boron and silicon, TM is choose from Co (cobalt) and Ni (nickel) at least a, L is from by Al (aluminium), V (vanadium), Cr (chromium), Y (yttrium), Zr (zirconium), Mo (molybdenum), Nb (niobium), that chooses in the group that Ta (tantalum) and W (tungsten) constitute is at least a, and find to obtain high magnetic and good noncrystalline formation ability, can obtain by having the block elements that the described described alloy of forming is made by described amorphous alloy is suitably handled, ember, thin strip and powder.
For example, the amorphous soft magnetic with described composition has good noncrystalline and forms ability, and available magnetic core thickness is 0.5mm or thicker, and cross-sectional area is 5mm
2Or littler, these sizes never occur traditionally, and it is high and have a high saturation magnetic flux metric density at the magnetic permeability in broadband or broadband.
For example, with regard to noncrystalline magnetic band with described composition, by described band is twined can obtain having similar magnetic can magnetic core and by adopt insulator with described tape lamination or the stacked magnetic core that forms with its performance of further raising.
For example, with regard to noncrystalline Magnaglo with described composition, by described powder suitably being mixed with adhesive and using rolled-up stock or molding die to carry out molded, and by powder surface being carried out oxidation processes or insulation coating, the dust core that can obtain having similar excellent performance.
That is to say, according to the present invention, be (Fe when passing through to select the composition expression formula to determine selected alloy composite
1-αTM
α)
100-w-x-y-zP
wB
xL
ySi
zThe time, can obtain excellent magnetic, the amorphous soft magnetic powder of the economy that noncrystalline formation ability height and powder filling capacity are fabulous, wherein contain the unavoidable impurities element, 0≤α≤0.98 wherein, 2 atom %≤w≤16 atom %, 2 atom %≤x≤16 atom %, 0 atom %＜y≤10 atom %, 0 atom %≤z≤8 atom %, TM is choose from Co and Ni at least a, L is from by Al, V, Cr, Y, Zr, Mo, Nb, that chooses in the group that Ta and W constitute is at least a, in addition, owing to use rolled-up stock or molding die or analog, so that according to a kind of suitable manufacturing process, by resulting powder being carried out oxidation processes or coating insulating barrier, resulting powder is formed molded product, produce dust core, so obtain the dust core of high magnetic permeability, this dust core is the magnetic permeability characteristic good on the broadband, therefore this never occurs under conventional situation, and the manufacturing cost of the high frequency magnetic core of being made by the soft magnetic material with high saturation magnetic flux metric density and high resistivity is lower.In addition, by twine a last circle or a multi-turn coil around described high frequency magnetic core, can make the inductance component of low-cost and high-performance, this never occurs under conventional situation, and therefore this inductance component is highly profitable industrial.
Wherein, first example according to the of the present invention first basic composition provides a kind of amorphous magnetic alloy, and the expression formula of its composition is Fe
100-w-x-yP
wB
xL
y(wherein Fe is a main component, can contain unavoidable impurities, L is at least a element of choosing from the group that is made of Al, V, Cr, Y, Zr, Mo, Nb, Ta and W, 2 atom %≤w≤16 atom %, 2 atom %≤x≤16 atom %, 0 atom %＜y≤10 atom %), it is good that the vitrifying of this alloy forms ability, soft magnet performance is good, and has the supercooled liquid scope.
According to second example of the present invention, a kind of amorphous magnetic alloy is provided, the expression formula of its composition is Fe
100-w-x-yP
wB
xL
ySi
zWherein Fe is a main component, can contain unavoidable impurities, L is at least a element of choosing from the group that is made of Al, V, Cr, Y, Zr, Mo, Nb, Ta and W, 2 atom %≤w≤16 atom %, 2 atom %≤x≤16 atom %, 0 atom %＜y≤10 atom %, 0 atom %＜z≤8 atom %, it is good that the vitrifying of this alloy forms ability, soft magnet performance is good, and has the supercooled liquid scope.
According to the 3rd example of the present invention, a kind of amorphous magnetic alloy is provided, the expression formula of its composition is (Fe
1-αTM
α)
100-w-x-yP
wB
xL
yWherein Fe is a main component, can contain unavoidable impurities, and TM is at least a element of choosing from Co and Ni, L is at least a element of choosing from the group that is made of Al, V, Cr, Y, Zr, Mo, Nb, Ta and W, 0＜α≤0.98,2 atom %≤w≤16 atom %, 2 atom %≤x≤16 atom %, 0 atom %＜y≤10 atom %, it is good that the vitrifying of this alloy forms ability, and soft magnet performance is good, and has the supercooled liquid scope.
According to the 4th example of the present invention, a kind of amorphous magnetic alloy is provided, the expression formula of its composition is (Fe
1-αTM
α)
100-w-x-yP
wB
xL
ySi
z, wherein Fe is a main component, can contain unavoidable impurities, TM is at least a element of choosing from Co and Ni, L is at least a element of choosing from the group that is made of Al, Mo, Nb, Ta, W, V and Cr, 0＜α≤0.98,2 atom %≤w≤16 atom %, 2 atom %≤x≤16 atom %, 0 atom %＜y≤10 atom %, 0 atom %＜z≤8 atom %, it is good that the vitrifying of this alloy forms ability, soft magnet performance is good, and has the supercooled liquid scope.
As mentioned above, in the present invention, soft magnet performance and noncrystalline form ability and are improved by described composition limiting and making it have the supercooled liquid scope.According to the present invention, when the supercooled liquid scope surpassed 20 ℃, soft magnet performance was better and noncrystalline formation ability is stronger.And supercooled liquid scope medium viscosity reduces rapidly.Therefore can utilize VISCOUS FLOW deformation to process.
According to the present invention, in aforementioned arbitrary example, provide a kind of noncrystalline soft magnetic components, when temperature raise, the noncrystalline soft magnetic components had 520 ℃ or begin temperature less than 520 ℃ glass transition.
According to the present invention, main component is Fe, P and B, and glass transition temperature is 450 ℃ to 500 ℃.Such temperature is than the disclosed conventional compositions (Fe with supercooled liquid scope of non-patent literature 3 (Mat.Trans.43 (2002) pp.766-769)
0.75Si
0.10B
0.15)
96Nb
4Low about 100 ℃.Because the temperature required decline of heat treatment, thereby be convenient to heat-treat, and by in addition heat-treat for a long time being lower than under the temperature of glass transition temperature, can improve soft magnet performance widely, thereby can heat-treat simultaneously with copper cash, bobbin, resin etc. such as the noncrystalline magnetic element of band or dust core.
To be set forth the second basic composition of amorphous soft magnetic of the present invention now, this amorphous soft magnetic also contains (Ti in addition in the aforementioned first basic composition
pC
qMn
rCu
s).
The present inventor finds, is (Fe by selecting the expression formula with the composition of determining selected alloy
1-αTM
α)
100-w-x-y-zP
wB
xL
ySi
z(Ti
pC
qMn
rCu
s), can obtain excellent magnetic and noncrystalline and form the high amorphous soft magnetic powder of ability, wherein contain unavoidable impurities, 0≤α≤0.3,2 atom %≤w≤18 atom %, 2 atom %≤x≤18 atom %, 15 atom %＜w+x≤23 atom %, 1 atom %≤y≤5 atom %, 0 atom %≤z≤4 atom %, TM is choose from Co and Ni at least a, L is from by Al, Cr, that chooses in the group that Mo and Nb constitute is at least a, 0≤p≤0.3,0≤q≤0.5,0≤r≤2,0≤s≤1, each p wherein, q, r and s are illustrated in Fe, TM, P, B, L, the gross mass of Si is 100 o'clock an interpolation ratio, and finds to obtain stronger magnetic and good noncrystalline formation ability, can obtain by having the block elements that the described described alloy of forming is made by described amorphous alloy is suitably processed, ember, thin strip and powder.
For example, the amorphous soft magnetic with described composition has good performance and has showed that good noncrystalline forms ability, and available magnetic core thickness is 0.5mm or thicker, and cross-sectional area is 5mm
2Or littler, these sizes are never to occur under the conventional situation, and it is high and have a high saturation magnetic flux metric density at wide band magnetic permeability.
For example, with regard to noncrystalline magnetic band with described composition, by described band is twined can obtain having similar magnetic can magnetic core and by utilize insulator with described tape lamination or the stacked magnetic core that forms with its performance of further raising.
For example, with regard to noncrystalline Magnaglo with described composition, by described powder suitably being mixed with adhesive and using rolled-up stock or molding die to carry out molded, and by the surface of powder being carried out oxidation processes or at the surface applied insulating barrier of powder, the dust core that can obtain having similar excellent performance.
That is to say, according to the present invention, be (Fe when passing through to select the composition expression formula to determine selected alloy composite
1-αTM
α)
100-w-x-y-zP
wB
xL
ySi
z(Ti
pC
qMn
rCu
s) time, can obtain excellent magnetic and noncrystalline and form the high amorphous soft magnetic powder of ability through improving, wherein contain the unavoidable impurities element, wherein TM is choose from Co and Ni at least a, L is from by Al, Cr, that chooses in the group that Mo and Nb constitute is at least a, 0≤α≤0.3,2 atom %≤w≤18 atom %, 2 atom %≤x≤18 atom %, 15 atom %≤w+x≤23 atom %, 1 atom %≤y≤5 atom %, 0 atom %≤z≤4 atom %, 0≤p≤0.3,0≤q≤0.5,0≤r≤2,0≤s≤1, each p wherein, q, r and s are illustrated in Fe, TM, P, B, L, the gross mass of Si is 100 o'clock an interpolation ratio, in addition, owing to use rolled-up stock or analog, so that according to suitable manufacturing process, the powder that will carry out oxidation processes or the acquisition of coating insulating barrier forms molded product, produce dust core, so obtain the dust core of high magnetic permeability, this dust core is adapted at representing on the broadband magnetic good magnetic permeability characteristic, therefore this never occurs under conventional situation, and the manufacturing cost of the high frequency magnetic core of being made by the soft magnetic material with high saturation magnetic flux metric density and high resistivity is lower.
Wherein, be example with basic composition 2 of the present invention, a kind of amorphous magnetic alloy is provided, the expression formula of its composition is as follows, and it is very high that the noncrystalline of described alloy forms ability, and soft magnet performance is good, and has the supercooled liquid scope.
That is to say that according to the example about basic composition 2 of the present invention, provide a kind of amorphous soft magnetic, the expression formula of its composition is (Fe
1-αTM
α)
100-w-x-yP
wB
xL
ySi
z(Ti
pC
qMn
rCu
s), wherein TM is choose from Co and Ni at least a, L is from by Al, Cr, that chooses in the group that Mo and Nb constitute is at least a, 0≤α≤0.3,2≤w≤18,2≤x≤18,15≤w+x≤23,1≤y≤5,0≤z≤4,0≤p≤0.3 quality %, 0≤p≤0.3,0≤q≤0.5,0≤r≤2,0≤s≤1, each p wherein, q, r and s are illustrated in Fe, TM, P, B, L, the gross mass of Si is 100 o'clock an interpolation ratio, and Tg (being glass transition temperature) is 520 ℃ or lower, and Tx (being crystallization start temperature) is 550 ℃ or lower, and the supercooled liquid scope of being represented by Δ Tx=Tx-Tg is 20 ℃ or bigger.
Amorphous soft magnetic is characterised in that, it has aforementioned component, and Tg (being glass transition temperature) is 520 ℃ or lower, and Tx (being crystallization start temperature) is 550 ℃ or lower, and is 20 ℃ or bigger by the supercooled liquid scope that Δ Tx=Tx-Tg represents.Because Tg is 520 ℃ or lower, therefore being expected at the heat treatment temperature that is lower than conventional temperature annealing effect occurs, thereby can heat-treat after magnet-wire is twined.When having served as cold liquid scope above 20 ℃, soft magnet performance is fabulous and noncrystalline formation ability is very high.And supercooled liquid scope medium viscosity reduces rapidly, therefore can utilize VISCOUS FLOW deformation to process.
According to the present invention, amorphous soft magnetic has the first or second basic composition, and its Curie temperature is 240 ℃ or higher.In this amorphous soft magnetic, if Curie temperature is low, magnetic property so at high temperature will worsen.Therefore, Curie temperature is limited in 240 ℃ or higher.
In addition, the present inventor finds, by twine a last circle or a multi-turn coil around the high frequency magnetic core of making by amorphous soft magnetic powder with aforementioned basic composition 1 or 2, can make the inductance component of low-cost and high-performance, this never occurs under conventional situation.
In addition, the present inventor finds, is limited by the granular size to noncrystalline soft magnetic metal powder (it forms expression formula as aforementioned basic composition 1 or 2), can obtain better dust core aspect the core loss under high frequency.
In addition, the present inventor finds, by enclosing at winding around under the state in the magnetic, adopts press molding that magnet and winding around are formed integral body together, can obtain being suitable for the inductance component of big electric current under the high frequency.
Here, for the resistivity that increases moulded product it is carried out molded before, alloy powder can be by thermal oxidation in air, can under the temperature that is equal to or higher than as the softening point of the resin of adhesive, carry out molded, so that obtain the high density molded product, perhaps can carry out molded in the supercooled liquid scope of alloy powder for the density that further increases moulded product.
Particularly, by carrying out molded to amorphous soft magnetic powder with aforementioned basic composition 1 and the mixture that adds the adhesive of described amorphous soft magnetic powder with the predetermined quality percentage, can obtain described moulded product, the composition expression formula of described basic composition 1 is (Fe
1-αTM
α)
100-w-x-y-zP
wB
xL
ySi
zWherein contain the unavoidable impurities element, 0≤α≤0.98,2 atom %≤w≤16 atom %, 2 atom %≤x≤16 atom %, 0 atom %＜y≤10 atom %, 0 atom %≤z≤8 atom %, TM is choose from Co and Ni at least a, and L is choose from the group that is made of Al, V, Cr, Y, Zr, Mo, Nb, Ta and W at least a.
About having the amorphous soft magnetic powder of aforementioned basic composition 2, the expression formula of its composition is (Fe
1-αTM
α)
100-w-x-y-zP
wB
xL
ySi
z(Ti
pC
qMn
rCu
s), wherein contain the unavoidable impurities element, 0≤α≤0.3,2 atom %≤w≤18 atom %, 2 atom %≤x≤18 atom %, 15 atom %≤W+X≤23 atom %, 1 atom %≤y≤5 atom %, 0 atom %≤z≤4 atom %, 0≤p≤0.3 quality %, 0≤q≤0.5 quality %, 0≤r≤2 quality %, 0≤s≤1 quality %, TM is choose from Co and Ni at least a, L is choose from the group that is made of Al, Cr, Mo and Nb at least a.
To be elaborated respectively the forming of alloy composite alloy composite of noncrystalline soft magnetic metal powder of the present invention herein.
Main component Fe element is used to produce magnetic and is that to obtain the high saturation magnetic flux metric density necessary.Part Fe can be replaced by Co that represents with TM or Ni.With regard to Co, if require that the high saturation magnetic flux metric density is arranged, so the content of Co be preferably 0.05 or above and 0.2 or below.On the other hand, with regard to Ni, adding Ni can increase the supercooled liquid scope and reduce Bs, so the content of Ni is preferably 0.1 or still less.Just reduce material cost, preferably do not add expensive Co or Ni.
According to the present invention, P is necessary element, and its content is 2 atom % or above and 18 atom % or following, but its content is 16 atom % or following when being added with Ti, C, Mn and Cu.The content of P is defined as 2 atom % or above and 18 atom % or following or 16 atom % or following reason to be, when the content of P is lower than 2 atom %, the supercooled liquid scope will reduce and noncrystalline formation ability can reduce, and when its content surpassed 18 atom % or 16 atom %, Curie temperature and noncrystalline formed that ability all can reduce and the supercooled liquid scope also can reduce.Preferably the content with P is set in 2 atom % or above and 12 atom % or following.
According to the present invention, B is essential element, and its content is 2 atom % or above and 18 atom % or following, but its content is 16 atom % or following when being added with Ti, C, Mn and Cu.The content of B is defined as 2 atom % or above and 18 atom % or following or 16 atom % or following reason to be, when the content of B is lower than 2 atom %, Curie temperature and noncrystalline form that ability all can reduce and the supercooled liquid scope also can reduce, and when its content surpassed 18 atom % or 16 atom %, the supercooled liquid scope will reduce and noncrystalline formation ability can reduce.Preferably the content with B is set in 6 atom % or above and 16 atom % or following.
When being added with Ti, C, Mn and Cu, the total content of P and B is 15 atom % or above and 23 atom % or following.The total content of P and B is defined as 15 atom % or above and 23 atom % or following reason is, when described total content was lower than 15 atom % or surpasses 23 atom %, the supercooled liquid scope will reduce and noncrystalline forms ability and can reduce.The total content of P and B is preferably 16 atom % or above and 22 atom % or following.
L is the element that obviously improves the noncrystalline formation ability of Fe-P-B alloy, and its content is 10 atom % or following, but its content is 5 atom % or following when being added with Ti, C, Mn and Cu.According to the present invention, the content of L is defined as 10 atom % or following or 5 atom % or following reason is that when the content of L surpassed 10 atom % or 5 atom %, saturation flux density can significantly reduce and Curie temperature also can significantly reduce.The content of L is defined as surpassing 1% or 0% reason and is,, can't form amorphous phase when the content of L is 1% or following or 0% or when following.
Si can be used for replacing the P of Fe-P-B alloy and the element of B, and can improve noncrystalline formation ability, and its content is 8 atom % or following, but its content is 4 atom % or following when being added with Ti, C, Mn and Cu.The content of Si is defined as 8 atom % or following or 4 atom % or following reason to be, when the content of Si surpasses 8 atom % or 4 atom %, glass transition temperature and crystallization temperature all can rise, and the supercooled liquid scope then can reduce and noncrystalline formation ability can reduce.
Ti, Mn and Cu are the elements that effectively improves the corrosion resistance of alloy.The content of Ti is defined as 0.3 quality % or following reason is, when the content of Ti surpassed 0.3 quality %, noncrystalline formed ability and will significantly reduce.The content of Mn is defined as 2 quality % or following reason is, when the content of Mn surpassed 2 quality %, saturation flux density will significantly reduce and Curie temperature also can significantly reduce.The content of Cu is defined as 1 quality % or following reason is, when the content of Cu surpassed 1 quality %, noncrystalline formed ability and will significantly reduce.C is the element that effectively improves the Curie temperature of alloy.The content of C is defined as 0.5 quality % or following reason is, when the content of C surpassed 0.5 quality %, noncrystalline formed ability and will significantly reduce, as the situation of Ti.
The amorphous soft magnetic powder adopts water atomization method (water atomizing method) or aerosolization method (gas atomizing method) to produce, and preferably its granularity at least 50% or more than be 10 μ m or bigger.The water atomization method is produced the method for a large amount of alloy powders in particular at low cost, and to adopt this method to produce described powder be very useful industrial.Yet, with regard to traditional noncrystalline composition, its granular size be 10 μ m or bigger alloy powder by crystallization, so its magnetic property significantly worsens, the result, product yield significantly reduces, thereby this point has hindered its industrialization.On the other hand and since when granular size be 150 μ m or more hour, the alloy composite of noncrystalline soft magnetic metal powder of the present invention is easy to amorphous materialization, so product yield is higher, thereby be highly profitable with regard to this point of cost.In addition because the alloy powder that adopts the water atomization method to produce has been formed with suitable oxide-film on powder surface, so by with mixed with resin in alloy powder and form the magnetic core that moulded product can easily obtain having high resistivity.The alloy powder of producing with regard to the employing water atomization method of this place explanation and adopting with regard in the alloy powder that the aerosolization method produces any, if it is being equal to or less than under the temperature conditions of crystallization temperature in air by heat treatment, will form better oxidation film so, therefore improve the resistivity of the magnetic core of making by this alloy powder.This point can reduce core loss.On the other hand, with regard to the high-frequency inductor parts, known metal dust by use fine particle size can reduce eddy current loss.Yet, with regard to usually known alloy composite, have shortcoming, promptly when the center granular size be that mean particle size is 30 μ m or more hour, powder at production period by significantly oxidation, the performance that therefore is difficult to utilize the powder of common water atomization device fabrication to obtain being scheduled to.On the other hand, because the alloy corrosion resistance of noncrystalline soft magnetic metal powder is very high, so even the particles of powder size still can relatively easily make the good powder of the performance with a spot of oxygen in thinner hour, this is more useful.
Basically, by will being mixed in the noncrystalline soft magnetic metal powder with 10 quality % or lower amount, and using rolled-up stock or adopt the molded moulded product that obtains, make high frequency magnetic core thus such as the adhesive of silicone resin.
By in rolled-up stock or moulded parts, carrying out compression forming, can obtain moulded product thus to the noncrystalline soft magnetic metal powder with the mixture that 5 quality % or amount still less are added to adhesive wherein.In this case, the powder filling rate of moulded product is 70% or more, when applying 1.6 * 10
4Magnetic density is 0.4T or bigger during the magnetic field of A/m, and resistivity is 1 Ω cm or bigger.When magnetic density is that 0.4T or more and resistivity are 1 Ω cm or when bigger, the performance of moulded product is better than FERRITE CORE, so its validity obtains increasing.
In addition, by under the temperature conditions of the softening point that is equal to or higher than adhesive, in rolled-up stock, carry out compression forming to the noncrystalline soft magnetic metal powder with the mixture that 3 quality % or amount still less are added to adhesive wherein, can obtain moulded product thus.In this case, the powder filling rate of moulded product is 80% or more, when applying 1.6 * 10
4Magnetic density is 0.6T or bigger during the magnetic field of A/m, and resistivity is 0.1 Ω cm or bigger.When magnetic density is that 0.6T or more and resistivity are 0.1 Ω cm or when bigger, the performance of moulded product is better than current commercial dust core, so its serviceability obtains increasing.In addition,, carry out compression forming, can obtain moulded product thus to the noncrystalline soft magnetic metal powder with the mixture that 1 quality % or amount still less are added to adhesive wherein by in the temperature range of the supercooled liquid scope of noncrystalline soft magnetic metal powder.In this case, the powder filling rate of moulded product is 90% or more, when applying 1.6 * 10
4Magnetic density is 0.9T or bigger during the magnetic field of A/m, and resistivity is 0.01 Ω cm or bigger.When magnetic density is that 0.9T or more and resistivity are 0.01 Ω cm or when bigger, the magnetic density of moulded product equals the magnetic density of the laminate steel core of amorphous and high silicon content in the practical ranges substantially.Yet the magnetic hysteresis loss of the moulded product here is little, and its core loss characteristic corresponding to its high resistivity is very good, has therefore further improved its validity as magnetic core.
And, if after molded, all heat-treat being equal to or higher than under the temperature conditions of its Curie temperature aforementioned each moulded product of giving as high frequency magnetic core, as the heat treatment of removing strain, can further reduce core loss so and can further improve its validity as magnetic core.
In the powder that makes by amorphous soft magnetic with basic composition 1 of the present invention or 2, Tg (being glass transition temperature) is 520 ℃ or lower, Tx (being crystallization start temperature) is 550 ℃ or lower, and the supercooled liquid scope of being represented by Δ Tx=Tx-Tg is 20 ℃ or bigger.Because Tg is 520 ℃ or lower, so annealing effect is expected at the heat treatment temperature that is lower than conventional temperature, thereby can heat-treat after magnet-wire is twined.When having served as cold liquid scope above 20 ℃, soft magnet performance is fabulous and noncrystalline formation ability is very high.And supercooled liquid scope medium viscosity reduces rapidly, therefore can utilize VISCOUS FLOW deformation to process.
In addition, the present invention can be frequency when being 1kHz initial permeability be 5000 or higher noncrystalline soft magnetism band.And the present invention can form the block magnetic element of noncrystalline, and its thickness is 0.5mm or thicker, and cross-sectional area is 0.15mm
2Or it is bigger.
Here, according to the present invention, by forming as above-mentioned selection and optimization, can adopt metal mould cast method to make the block magnetic element of noncrystalline, its diameter is that 1.5mm and its noncrystalline form ability apparently higher than traditional noncrystalline band, therefore can be different from lamination or the compression forming of powder or the formation of the block elements that curing molding is realized magnetic core of band.
When on the part magnetic circuit, forming breach as required and twining a circle or multi-turn coil, can make the inductance component as product of its good characteristic that shows high magnetic permeability in high-intensity magnetic field around this high frequency magnetic core.
Now with reference to accompanying drawing the present invention is set forth in further detail.
With reference to Fig. 1, it illustrates an example according to the basic structure of high frequency magnetic core 1 of the present invention, and its state makes high frequency magnetic core 1 form the shape of annular slab for using aforementioned amorphous soft magnetic powder.
With reference to Fig. 2, show the inductance component 10 that forms around the high frequency magnetic core 1 by coil 3 is wrapped in, wherein, coil 3 twines predetermined times around the high frequency magnetic core 1 of annular slab shape, form the inductance component 10 with lead-out wire part 3a and 3b thus.
With reference to Fig. 3, it illustrates another example according to the basic structure of high frequency magnetic core 1 of the present invention, wherein, use aforementioned amorphous soft magnetic powder to make high frequency magnetic core 1 form the shape (annular plate shape) of annular slab, on its part magnetic circuit, form breach 2 then.
With reference to Fig. 4, it illustrates the inductance component 20 that forms around the high frequency magnetic core 1 with breach 2 by coil 3 is wrapped in, wherein, coil 3 twines predetermined times around the high frequency magnetic core with breach 21 of annular slab shape, forms the inductance component 20 with lead-out wire part 3a and 3b thus.
By (it has aforementioned noncrystalline metal and forms to the noncrystalline soft magnetic metal powder, and maximum particle size is screen size 45 μ m or littler, medium particle diameter is 30 μ m or littler) and carry out molded with the mixture that 10 quality % or amount still less are added to adhesive wherein, can obtain having the dust core of extraordinary low loss characteristic under high frequency, this never occurs under conventional situation.By coil being applied on this dust core, can obtain the good inductance component of Q quality factor.In addition,, adopt compression forming that magnet and winding around are formed integral body together, can obtain being suitable for the inductance component of big electric current under the high frequency by enclosing at winding around under the state in the magnet.
The concrete reason that the particles of powder size is limited is, if the screen size of maximum particle size surpasses 45 μ m, the Q quality factor of high-frequency region will worsen so, in addition, unless the centrophyten size is 30 μ m or littler, the Q quality factor under 500kHz or higher frequency can not surpass 40.In addition, unless the centrophyten size is 20 μ m or littler, the Q value under 1MHz or higher frequency (1/tan δ) can not become 50 or bigger.Because the resistivity of the alloy of amorphous soft magnetic powder itself exceeds about 2 to 10 times of traditional material, the Q quality factor preferably become big under the identical situation of granular size.If whether the Q quality factor are identical unimportant, can reduce the powder manufacturing cost by the scope that increases available granular size so.
With reference to Fig. 5, it illustrates the another example according to the basic structure of high-frequency inductor parts 103 of the present invention, wherein, under the state of enclosing in the magnet 8 at winding around 6, adopt compression forming to integrate, can form inductance component 103 by magnet 8 and the winding around element 7 that aforementioned amorphous soft magnetic powder is made.The coil extension that numeral " 5 " expression is extended from winding around 6.
According to the present invention, the such state of " noncrystalline " expression wherein adopts common X-ray diffraction method that the surface of band or powder is measured, and the X-ray diffraction that obtains thus (XRD) resolution chart only is a broad peak.On the contrary, when spike occurring, can be judged to be " crystalline phase " owing to crystalline phase.
According to the present invention, when in the inert gas atmosphere such as Ar atmosphere, when the temperature of amorphous band or powder raises, during temperature raises, after the glass transition phenomenon occurring crystalline polamer appears.The beginning temperature of this glass transition phenomenon is represented with glass transition temperature (Tg), and the temperature range between glass transition temperature (Tg) and crystallization temperature (Tx) is represented with supercooled liquid scope (Tx-Tg).Be set in the rate of heat addition under the condition of 40K/min glass transition temperature, crystallization temperature and supercooled liquid scope are carried out assessment.
[example]
To be elaborated the present invention with example below.
(example 1 to 15)
Respectively simple metal material Fe, P, B, Al, V, Cr, Y, Zr, Nb, Mo, Ta and W are carried out weighing according to predetermined alloy composite, carrying out high-frequency heating with its fusing, make foundry alloy thus then through in the Ar atmosphere pressure-reducing chamber of finding time.Afterwards, utilize prepared foundry alloy, use single-roller method to make the band that thickness is respectively 20 μ m and 200 μ m by regulating rotary speed.
For relatively, make foundry alloy by high-frequency heating with composition identical with commercial METGLAS 2605-S2, adopt single-roller method to form the band of 20 μ m and 200 μ m then.
With regard to the band of each 200 μ m, use X-ray diffraction method that the slowest free coagulation surface of the cooling rate that does not contact with the copper roll is measured, obtain the X-ray diffraction resolution chart thus, decidable is " amorphous phase " when resulting X-ray diffraction resolution chart has only broad peak, and then decidable is " crystalline phase " in other cases.In addition, use the band of 20 μ m, hot property is judged by differential scanning calorimetry or calorimetry (DSC).In view of the above glass transition temperature and crystallization temperature are measured, and therefrom calculated the supercooled liquid scope.With regard to magnetic property, the band of 20 μ m is formed the magnetic core of winding, by the impedance analysis device initial permeability is measured then, and by DC B-H tracing instrument coercive force is measured.In this case, under glass transition temperature, in Ar atmosphere, each sample carried out 5 minutes heat treatment.Those samples that do not have glass transition temperature carry out 5 minutes heat treatment respectively under the temperature that is lower than 30 ℃ of crystallization temperatures.
As shown in table 1, because the alloy composite of example 1 to 15 drops in the compositing range of the present invention, so they have the supercooled liquid scope respectively, and vitrifying formation ability is good, and soft magnet performance is also fine.Fig. 6 is the Fe with different-thickness
78P
8B
10Mo
4The XRD result curve figure of band.As seen from Figure 6, the X-ray diffraction resolution chart up to the broad peak of 200 μ m, is " amorphous phase " therefore only.This point equally also is suitable for other example.In fact, being difficult to produce thickness is 1 μ m or thinner band.On the other hand, comparative example 2,4 and 5 does not have the supercooled liquid scope, and vitrifying formation ability is lower, and soft magnet performance is relatively poor.In the comparative example 1 and 3 each all has the supercooled liquid scope, although it is smaller, it is lower that vitrifying forms ability, and can not to make thickness be 200 μ m or thicker band.
(example 16 to 24)
Respectively simple metal material Fe, P, B, Al, V, Cr, Nb, Mo, Ta, W and Si are carried out weighing according to predetermined alloy composite, carrying out high-frequency heating with its fusing, make foundry alloy thus then through in the decompression Ar atmosphere of finding time indoor.Afterwards, utilize prepared foundry alloy, use single-roller method to make the band that thickness is respectively 20 μ m and 200 μ m by regulating rotary speed.
With regard to the band of each 200 μ m, use X-ray diffraction method that the slowest free coagulation surface of the cooling rate that does not contact with the copper roll is measured, obtain the X-ray diffraction resolution chart thus, decidable is " amorphous phase " when resulting X-ray diffraction resolution chart has only broad peak, and then decidable is " crystalline phase " in other cases.In addition, use the band of 20 μ m, hot property is judged by DSC.In view of the above glass transition temperature and crystallization temperature are measured, and therefrom calculated the supercooled liquid scope.With regard to magnetic property, the band of 20 μ m is formed the magnetic core of winding, by the impedance analysis device initial permeability is measured then, and by DC B-H tracing instrument coercive force is measured.In this case, under glass transition temperature, in Ar atmosphere, each sample carried out 5 minutes heat treatment.Those samples that do not have glass transition temperature carry out 5 minutes heat treatment respectively under the temperature that is lower than 30 ℃ of crystallization temperatures.
As shown in table 2, because the alloy composite of example 1624 drops in the compositing range of the present invention, so they have the supercooled liquid scope respectively, and vitrifying formation ability is good, and soft magnet performance is also fine.On the other hand, comparative example 6 does not have the supercooled liquid scope, and vitrifying formation ability is lower, and therefore can not make thickness is 200 μ m or thicker band, and the soft magnet performance of comparative example 6 is relatively poor.
(example 25 to 29)
Respectively simple metal material Fe, Co, Ni, P, B and Mo are carried out weighing according to predetermined alloy composite, carrying out high-frequency heating with its fusing, make foundry alloy thus then through in the Ar atmosphere pressure-reducing chamber of finding time.Afterwards, utilize prepared foundry alloy, use single-roller method to make the band that thickness is respectively 20 μ m and 200 μ m by regulating rotary speed.
With regard to the band of each 200 μ m, use X-ray diffraction method that the slowest free coagulation surface of the cooling rate that does not contact with the copper roll is measured, obtain the X-ray diffraction resolution chart thus, decidable is " amorphous phase " when resulting X-ray diffraction resolution chart has only broad peak, and then decidable is " crystalline phase " in other cases.In addition, use the band of 20 μ m, hot property is judged by DSC.In view of the above glass transition temperature and crystallization temperature are measured, and therefrom calculated the supercooled liquid scope.With regard to magnetic property, the band of 20 μ m is formed the magnetic core of winding, by the impedance analysis device initial permeability is measured then, and by DC B-H tracing instrument coercive force is measured.In this case, under glass transition temperature, in Ar atmosphere, each sample carried out 5 minutes heat treatment.Those samples that do not have glass transition temperature carry out 5 minutes heat treatment respectively under the temperature that is lower than 30 ℃ of crystallization temperatures.
As shown in table 3, because the alloy composite of example 25 to 29 drops in the compositing range of the present invention, so they have the supercooled liquid scope respectively, and vitrifying formation ability is good, and soft magnet performance is also fine.On the other hand, although comparative example 7 has the supercooled liquid scope, and have excellent vitrifying formation ability, it does not at room temperature have magnetic.
(example 30 to 33)
Respectively simple metal material Fe, Co, Ni, P, B, Mo and Si are carried out weighing according to predetermined alloy composite, carrying out high-frequency heating with its fusing, make foundry alloy thus then through in the Ar atmosphere pressure-reducing chamber of finding time.Afterwards, utilize prepared foundry alloy, use single-roller method to make the band that thickness is respectively 20 μ m and 200 μ m by regulating rotary speed.
With regard to the band of each 200 μ m, use X-ray diffraction method that the slowest free coagulation surface of the cooling rate that does not contact with the copper roll is measured, obtain the X-ray diffraction resolution chart thus, decidable is " amorphous phase " when resulting X-ray diffraction resolution chart has only broad peak, and then decidable is " crystalline phase " in other cases.In addition, use the band of 20 μ m, hot property is judged by DSC.In view of the above glass transition temperature and crystallization temperature are measured, and therefrom calculated the supercooled liquid scope.With regard to magnetic property, the band of 20 μ m is formed the magnetic core of winding, by the impedance analysis device initial permeability is measured then, and by DC B-H tracing instrument coercive force is measured.In this case, under glass transition temperature, in Ar atmosphere, each sample carried out 5 minutes heat treatment.Those samples that do not have glass transition temperature carry out 5 minutes heat treatment respectively under the temperature that is lower than 30 ℃ of crystallization temperatures.
As shown in table 4, because the alloy composite of example 30 to 33 drops in the compositing range of the present invention, so they have the supercooled liquid scope respectively, and vitrifying formation ability is good, and soft magnet performance is also fine.On the other hand, although comparative example 8 has the supercooled liquid scope, and have excellent vitrifying formation ability, it does not at room temperature have magnetic.
(example 34 to 36)
Respectively simple metal material Fe, P, B, Al, Nb and Mo are carried out weighing according to predetermined alloy composite, carrying out high-frequency heating with its fusing, make foundry alloy thus then through in the Ar atmosphere pressure-reducing chamber of finding time.Afterwards, utilize prepared foundry alloy, adopt the water atomization method to make the noncrystalline soft magnetic powder.
For relatively, make foundry alloy by high-frequency heating with composition identical with commercial METGLAS 2605-S2, adopt the water atomization method to form the noncrystalline soft magnetic powder then.
Resulting noncrystalline soft magnetic powder all is classified into 200 μ m or littler particle size, use X-ray diffraction method that it is measured then, obtain the X-ray diffraction resolution chart thus, decidable is " amorphous phase " when resulting X-ray diffraction resolution chart has only broad peak, and then decidable is " crystalline phase " in other cases.
As shown in table 5, because the alloy composite of example 34 to 36 drops in the compositing range of the present invention, so can adopt the water atomization method to make the noncrystalline soft magnetic powder.The Fe of Fig. 7 for having the variable grain size by classification
78P
8B
10Mo
4The XRD result curve figure of powder.As seen from Figure 7, the X-ray diffraction resolution chart up to the broad peak of 200 μ m, is " amorphous phase " therefore only.This point equally also is suitable for other example.On the other hand, comparative example 9 does not have vitrifying to form ability, and therefore resulting powder is in crystalline phase.Can not obtain the noncrystalline soft magnetic powder.
(example 37 to 60)
Respectively material Fe, Co, Ni, Fe-P, Fe-B, Fe-Si, Al, Fe-V, Fe-Cr, Y, Zr, Fe-Nb, Fe-Mo, Ta, W, Ti, C, Mn and Cu are carried out weighing according to predetermined alloy composite, carrying out high-frequency heating with its fusing, make foundry alloy thus then through in the Ar atmosphere pressure-reducing chamber of finding time.Afterwards, utilize prepared foundry alloy, use single-roller method to make the band that thickness is respectively 20 μ m and 200 μ m by regulating rotary speed.
For relatively, make foundry alloy by high-frequency heating with composition identical with commercial METGLAS 2605-S2, adopt single-roller method to form the band of 20 μ m and 200 μ m then.
With regard to the band of each 200 μ m, use X-ray diffraction method that the slowest free coagulation surface of the cooling rate that does not contact with the copper roll is measured, obtain the X-ray diffraction resolution chart thus, decidable is " amorphous phase " when resulting X-ray diffraction resolution chart has only broad peak, and then decidable is " crystalline phase " in other cases.In addition, use the band of 20 μ m, hot property is judged by DSC.In view of the above glass transition temperature and crystallization temperature are measured, and therefrom calculated the supercooled liquid scope.With regard to magnetic property, use the band of 20 μ m, and use vibrating sample magnetometer (VSM) that its saturation flux density is measured.
As show shown in 6-1 and the table 6-2, because the alloy composite of example 37 to 60 drops in the compositing range of the present invention, so they have the supercooled liquid scope respectively, and noncrystalline forms very capablely, soft magnet performance is also fine.On the other hand, comparative example 10,11,12,13,14,15,17 and 20 has only little or does not have the supercooled liquid scope, and noncrystalline to form ability lower.It is higher that comparative example 16,18 and 19 noncrystalline form ability, but Tc and Bs are then lower.In comparative example 15, the supercooled liquid scope is less, and it is lower that noncrystalline forms ability, and glass transition temperature is higher.
(example 61 to 70)
Respectively material Fe, Fe-P, Fe-B, Fe-Cr, Fe-Nb, Ti, C, Mn and Cu are carried out weighing according to predetermined alloy composite, carrying out high-frequency heating with its fusing, make foundry alloy thus then through in the Ar atmosphere pressure-reducing chamber of finding time.Afterwards, utilize prepared foundry alloy, use single-roller method to make each band that thickness is 50 μ m.
For relatively, make foundry alloy by high-frequency heating with composition identical with commercial METGLAS 2605-S2, adopt single-roller method to form the band of 50 μ m then.
Each band is carried out the rate of corrosion inspection.The band of 50 μ m is placed in the 1 standard NaCl solution, and weight change is checked, and goes out rate of corrosion from surface area and Time Calculation.Its result is as shown in table 7.
As shown in table 7, because the alloy composite of example 61 to 70 drops in the compositing range of the present invention, so their corrosion resistance is very strong, promptly their rate of corrosion is lower.On the contrary, the corrosion resistance of comparative example 21 is very low, and promptly its rate of corrosion is bigger.
(example 71 to 73)
Respectively material Fe, Fe-P, Fe-B, Fe-Cr, Fe-Nb, Ti, C, Mn and Cu are carried out weighing according to predetermined alloy composite, carrying out high-frequency heating with its fusing, make foundry alloy thus then through in the Ar atmosphere pressure-reducing chamber of finding time.Afterwards, utilize prepared foundry alloy, use single-roller method to make the band that thickness is 20 μ m.
For relatively, make foundry alloy by high-frequency heating with composition identical with commercial METGLAS 2605-S2, adopt single-roller method to form the band of 20 μ m then.
The band of each 20 μ m all is formed the magnetic core of winding, and the stacked part of magnetic core is measured initial permeability by the impedance analysis device then by inserting the bonded and insulation of silicone resin therebetween.In this case, 350 ℃ of heat treatments of in Ar atmosphere, each sample being carried out 60 minutes.On the other hand, to the sample made by METGLAS 2605-S2 425 ℃ of heat treatments of carrying out 60 minutes.
As shown in table 8, because the alloy composite of example 71 to 73 drops in the compositing range of the present invention, so their soft magnet performance is fine.On the contrary, the soft magnet performance of comparative example 22 is very poor.
(example 74 to 78)
Respectively material Fe, Fe-P, Fe-B, Fe-Cr, Fe-Nb, Ti, C, Mn and Cu are carried out weighing according to predetermined alloy composite, carrying out high-frequency heating with its fusing, make foundry alloy thus then through in the Ar atmosphere pressure-reducing chamber of finding time.Afterwards, utilize prepared foundry alloy, use single-roller method to make the band that thickness is 20 μ m to 170 μ m by regulating rotary speed.
For relatively, make foundry alloy by high-frequency heating with composition identical with commercial METGLAS 2605-S2, adopt single-roller method to form the band of 20 μ m then.
To each band sheet all carry out stackedly, to form stacked magnetic core, magnetic core width is 1mm, length is 16mm, thickness is 1mm.The band sheet is bonded together by silicone resin is inserted therebetween, and mutually insulated, uses after the coil of 1200 circles on each stacked magnetic core, by the impedance analysis device Ls and Q is measured.In this case, 350 ℃ of heat treatments of in Ar atmosphere, each sample being carried out 60 minutes.On the other hand, under 425 ℃, the sample that is made of METGLAS 2605-S2 carried out 60 minutes heat treatment.The measurement result of sample is as shown in table 9.
As shown in table 9, because the alloy composite of example 74 to 78 drops in the compositing range of the present invention, so their high-frequency soft magnetic performance is fine.On the contrary, because the thickness of comparative example 23 surpasses 150 μ m, so its high frequency characteristics is because eddy current loss and very poor.In addition, the composition of comparative example 24 drops on outside the compositing range of the present invention, its high-frequency soft magnetic poor performance.
(example 79 to 82)
Respectively material Fe, Fe-P, Fe-B, Fe-Cr, Fe-Nb, Ti, C, Mn and Cu are carried out weighing according to predetermined alloy composite, carrying out high-frequency heating with its fusing, make foundry alloy thus then through in the Ar atmosphere pressure-reducing chamber of finding time.Afterwards, utilize prepared foundry alloy, use the water atomization method to make powder.
For relatively, by high-frequency heating, make foundry alloy thus with composition identical with commercial METGLAS2605-S2, adopt the water atomization method to form powder then.
Resulting powder all is classified into 200 μ m or littler particle size, use X-ray diffraction method that it is measured then, obtain the X-ray diffraction resolution chart thus, decidable is " amorphous phase " when resulting X-ray diffraction resolution chart has only broad peak, and then decidable is " crystalline phase " in other cases.
As shown in table 10, because the alloy composite of example 79 to 82 drops in the compositing range of the present invention, so can adopt the water atomization method to make the noncrystalline soft magnetic powder.On the other hand, comparative example 25 and 26 does not have vitrifying to form ability, and therefore resulting powder is in crystalline phase.Can not obtain the noncrystalline soft magnetic powder.
(example 83 to 86)
Respectively material Fe, Fe-P, Fe-B, Fe-Cr, Fe-Nb, Ti, C, Mn and Cu are carried out weighing according to predetermined alloy composite, carrying out high-frequency heating with its fusing, make foundry alloy thus then through in the Ar atmosphere pressure-reducing chamber of finding time.Afterwards, utilize prepared foundry alloy, use the water atomization method to make the noncrystalline soft magnetic powder.Described powder is mixed, so that become graininess, then (10 tons/cm of 980MPa respectively with the silicone resin that is dissolved in the solvent of 5 quality %
2) pressure under described powder is pressed into overall diameter is 18mm, interior diameter is 12mm, thickness is the dust core of 3mm.
For relatively, the silicone resin in the solvent of being dissolved in of also being mixed with 5 quality % respectively for the Fe powder, Fe-Si-Cr powder and the ferro-silicon-aluminium powder that adopt the water atomization method to make is so that become graininess, then (10 tons/cm of 980MPa
2) pressure under described powder is pressed into overall diameter respectively is 18mm, interior diameter is 12mm, thickness is the dust core of 3mm.
With regard to resulting dust core, by the impedance analysis device initial permeability is measured, and Fe loss and density are measured by alternating-current B-H tracing instrument.In this case, in the heat treatment of in Ar atmosphere, each sample being carried out 60 minutes under 350 ℃.On the other hand, under 500 ℃, the sample that is made of Fe powder and Fe-Si-Cr powder is carried out 60 minutes heat treatment, and under 700 ℃, the sample that is made of the ferro-silicon-aluminium powder carried out 60 minutes heat treatment.Measured initial permeability, loss and density are as shown in table 11.
As shown in table 11, be appreciated that the dust core that constitutes owing to the noncrystalline soft magnetic powder by example 83 to 86 falls within the scope of the invention, so its loss is very low.On the other hand, comparative example 27 is the dust cores that are made of iron powder, and density is bigger, the non-constant of initial permeability and high-frequency loss.Equally in comparative example 28 and 29, the non-constant of loss.
(example 87 to 110)
At first,, respectively simple metal element material Fe, Co, Ni, P, B, Si, Mo, Al, V, Cr, Y, Zr, Nb, Ta and W are carried out weighing, make foundry alloy thus according to predetermined alloy composite as the powder production process.Afterwards, utilize prepared foundry alloy, use the water atomization method to make various soft-magnetic alloy powders.
Then, as the moulded product production process, resulting alloy powder all is classified into 45 μ m or littler particle size, then will be as the silicone resin of adhesive amount and described powder with 4 quality %, afterwards, use to have overall diameter and be 27mm, interior diameter is the rolled-up stock molding die of the groove of 14mm, at room temperature respectively described powder is applied (the about 12t/cm with 1.18GPa
2) pressure so that have the height 5mm, obtain the respective molded product thus.
In addition, after resulting moulded product is carried out resin solidification, weight and size to moulded product are measured, and are to twine the coil respectively have the suitable number of turns on the magnetic core respectively at moulded product then, make corresponding inductance component (each all as shown in Figure 2) thus.
Then, with regard to each resulting sample is inductance component, uses LCR to measure meter and under 100kHz, try to achieve magnetic permeability by inductance value, in addition, when applying with 1.6 * 10
4During the magnetic field of A/m, use dc magnetic energy measurement equipment that saturation flux density is measured.In addition, the upper surface and the lower surface of each magnetic core polished, carry out XRD (X-ray diffraction) then and measure to observe phase.The result is shown in table 12-1 and table 12-2.
The proportion of composing of corresponding sample has been shown in table 12, and when in the XRD figure case that obtains by the XRD measurement, only detecting the broad peak that is specific to amorphous phase, can be judged to be " amorphous phase ", and when observing the spike that causes owing to crystalline phase with broad peak, perhaps when only observing spike under the situation that is not having broad peak, can be judged to be " crystalline phase ".With regard to those samples with the composition that presents amorphous phase, carry out heat by DSC and analyze, so that glass transition temperature (Tg) and crystallization temperature (Tx) are measured, and definite for those all samples Δ Tx be 20 ℃ or bigger.Adopt direct current two-terminal method that the resistivity of respective molded product (magnetic core) is measured, and determine that all samples all have 1 Ω cm or bigger value preferably.
The rate of heat addition in DSC is set to 40K/min.Be appreciated that by example 87 to 89 and comparative example 30 to 33, when the content of P or B is lower than 2% or when being higher than 16%, can not form the amorphous phase that can obtain high magnetic permeability, and when the content of the content of P and B all 2% or above and 16% or following scope in the time, can form amorphous phase.Be appreciated that by example 90 to 92 and comparative example 34 and 35,, can not form amorphous phase, and be higher than 0% and be 10% or when following when the content of Mo, can form amorphous phase when the content of Mo is 0% or when being higher than 10%.By example 93 and 94 and comparative example 36 be appreciated that, even, also can form amorphous phase when adding 8% or during the Si of less amount scope.Be appreciated that by example 95 to 102, even when Mo is replaced by Al, V, Cr, Y, Zr, Nb, Ta or W, also can form amorphous phase.Be appreciated that by example 103 to 110 Fe can partly be replaced by Co and/or Ni, but is appreciated that by comparative example 37 and 38, if Fe is replaced fully, although obtained amorphous phase so, the magnetic density vanishing, so this is not suitable for the field of the invention.
(example 111 to 132)
At first,, respectively simple metal element material Fe, Co, Ni, P, B, Si, Mo, Al, V, Cr, Y, Zr, Nb, Ta, W, Ti, C, Mn and Cu are carried out weighing, make foundry alloy thus according to predetermined alloy composite as the powder production process.Afterwards, utilize prepared foundry alloy, use the water atomization method to make various soft-magnetic alloy powders.
Then, as the moulded product production process, resulting alloy powder all is classified into 45 μ m or littler particle size, then will be as the silicone resin of adhesive amount and described powder with 4 quality %, afterwards, use to have overall diameter and be 27mm, interior diameter is the rolled-up stock of the groove of 14mm, at room temperature respectively described powder is applied (the about 12t/cm with 1.18GPa
2) pressure therefore so that have the height of 5mm, obtain the respective molded product.
In addition, after resulting moulded product is carried out resin solidification, weight and size to moulded product are measured, and are to use the coil respectively have the suitable number of turns on the magnetic core respectively at moulded product then, make corresponding inductance component (each all as shown in Figure 2) thus.
Then, with regard to each resulting sample is inductance component, uses LCR to measure meter and under 100kHz, try to achieve magnetic permeability by inductance value, in addition, when applying with 1.6 * 10
4During the magnetic field of A/m, use dc magnetic energy measurement equipment that saturation flux density is measured.In addition, the upper surface and the lower surface of each magnetic core polished, carry out XRD (X-ray diffraction) then and measure to observe phase.The result is shown in table 13-1 and table 13-2.
The proportion of composing of corresponding sample has been shown in table 13-1 and table 13-2, and when in the XRD figure case that obtains by the XRD measurement, only detecting the broad peak that is specific to amorphous phase, can be judged to be " amorphous phase ", and when observing the spike that causes owing to crystalline phase with broad peak, perhaps when only observing spike under the situation that is not having broad peak, can be judged to be " crystalline phase ".With regard to those samples with the composition that presents amorphous phase, carry out heat by DSC and analyze, so that glass transition temperature (Tg) and crystallization temperature (Tx) are measured, and definite for those all samples Δ Tx be 20 ℃ or bigger.Adopt direct current two-terminal method that the resistivity of respective molded product (magnetic core) is measured, and determine that all samples all have 1 Ω cm or bigger value preferably.
As show shown in 13-1 and the table 13-2, because the alloy composite of example 111 to 132 drops in the compositing range of the present invention, so they have the supercooled liquid scope respectively, and noncrystalline formation ability is good, soft magnet performance is also fine.On the other hand, be appreciated that it is lower that the noncrystalline of comparative example 39 to 53 forms ability, therefore can only obtain crystalline phase, and can not obtain good magnetic property.
(example 133)
In example 133, adopt the water atomization method to make and consist of Fe
77P
10B
10Nb
2Cr
1Ti
0.1C
0.1Mn
0.1Cu
0.1Alloy powder, resulting then alloy powder is classified into 45 μ m or littler particle size, then it is carried out XRD and measures, and determines to be specific to the broad peak of amorphous phase afterwards.In addition, carry out heat analysis,, determine that thus Δ Tx (Tg-Tx) is 36 ℃ to measure glass transition temperature (Tg) and crystallization temperature (Tx) by DSC.Then, powder is remained below 400 ℃ of the temperature of glass transition temperature,, on powder surface, form oxide thus so that in atmosphere, carry out 0.5 hour heat treatment.
In addition, will join as the silicone resin of adhesive in the described powder that is formed with oxide, with 5%, 2.5%, 1% and 0.5% amount respectively to obtain powder separately.Use and have overall diameter and be 27mm, interior diameter is the rolled-up stock of the groove of 14mm, at room temperature, be higher than 150 ℃ of the resin softening temperature or respectively resulting powder is applied (about 12 tons/cm with 1.18GPa 480 ℃ of the supercooled liquid scope of noncrystalline soft magnetic metal powder
2) pressure therefore so that have the height of 5mm, obtain the respective molded product.
After resulting moulded product is carried out resin solidification, weight and size to moulded product are measured, be to use the coil respectively have the suitable number of turns on the magnetic core respectively at moulded product then, make corresponding inductance component (each all as shown in Figure 2) thus.
Then, with regard to each resulting inductance component of the 1st to the 12nd sample, the magnetic density that can cause powder filling rate (%), dc magnetic is (1.6 * 10
4During A/m) and dc resistivity (Ω cm) measure.The result is as shown in table 14.
Be appreciated that by table 14, when the addition (amount of resin) of adhesive surpasses 5%, can obtain comparing with iron oxygen magnetic core 〉=10E4 (=10
5) high resistivity, even and can not observe this effect by improving molding temperature yet, and just enough such as the molded condition of room temperature.Be appreciated that, when amount of resin is 5%, also can obtain 1 Ω cm or above high resistivity, but equally at room temperature carry out molded just enough.In addition, be appreciated that with regard to 2.5% amount of resin, when carrying out when molded, the powder filling rate is significantly improved under 150 ℃, increasing magnetic density, and obtained 0.1 Ω cm or above resistivity in addition.In addition, be appreciated that with regard to 1% or 0.5% amount of resin, when carrying out when molded at 480 ℃, the powder filling rate is significantly improved, increasing saturation flux density, and obtained 0.01 Ω cm or above resistivity in addition.
(example 134)
In example 134, inductance component corresponding to the 10th sample in example 133 is made, and uses by same alloy powder and same manufacture process and at 450 ℃ of high frequency magnetic cores that make through 0.5 hour heat treatment in nitrogen atmosphere and makes inductance component.In addition, for relatively, use and make inductance component as the sendust of core material, 6.5% the base amorphous material of silicon steel, Fe.Each inductance component but also can be as shown in Figure 4 the inductance component that has breach on the part magnetic circuit all as shown in Figure 2.With regard in these inductance components each, to the magnetic density that can cause by dc magnetic (1.6 * 10
4During A/m), dc resistivity (Ω cm), be used for the standardized magnetic permeability of inductance value and core loss (20kHz 0.1T) is measured.The result is as shown in Table 15.
Be appreciated that by table 15 magnetic density of inductance component of the present invention equals to use the magnetic density of the inductance component of the base amorphous magnetic core of Fe substantially, its core loss then is lower than the core loss of the inductance component that uses sendust core, and its performance is very good.In addition, be appreciated that the magnetic permeability and the core loss that have through the inductance component of heat treated magnetic core are improved, so its more excellent performance.
(example 135)
In example 135, respectively with the ratio shown in the table 16, the particle size that will have alloy composite shown in the table 16 and be screened by the standard filter screen separately is that 20 μ m or littler water atomized powder are added in the powder identical with the powder that makes according to example 133, obtains corresponding powder thus.
In addition, amount with 1.5 quality % will join in resulting each powder as the silicone resin of adhesive, use then to have overall diameter and be 27mm, interior diameter is the rolled-up stock of the groove of 14mm, at room temperature resulting powder is applied (about 12 tons/cm with 1.18GPa
2) pressure therefore so that have the height of 5mm, obtain the respective molded product.After molded, in 450 ℃ Ar atmosphere, moulded product is heat-treated.
Then, after resulting moulded product is carried out resin solidification, weight and size to moulded product are measured, and are to use the coil respectively have the suitable number of turns on the magnetic core respectively at moulded product then, make corresponding inductance component (each all as shown in Figure 2) thus.
Then, with regard to each resulting sample was inductance component, (20kHz 0.1T) measured to powder filling rate (%), magnetic permeability and core loss.The result is shown in table 16.
Be appreciated that by table 16 by adding the soft magnetic powder that has than granule to the noncrystalline metal dust, the powder filling rate of inductance component of the present invention is improved, so magnetic permeability also is improved.On the other hand, be appreciated that and since when addition above 50% the time, the effect of improvement is weakened, the core loss characteristic can extremely worsen, so addition is preferably 50% or still less.
(example 136)
In example 136, make and consist of Fe
77P
10B
10Nb
2Cr
1Ti
0.1C
0.1Mn
0.1Cu
0.1Alloy powder, make by changing creating conditions of water atomization method, make it have ratio of height to diameter shown in table 17 (aspect ratio), resulting then powder is classified into 45 μ m or littler particle size, then it is carried out XRD and measure, determine to be specific to the broad peak of amorphous phase thus.In addition, all powder is carried out heat analysis,, determine that thus supercooling temperature range delta Tx is 20 ℃ to measure glass transition temperature and crystallization temperature by DSC.
In addition, the amount with 3.0 quality % will join in the resulting powder, afterwards as the silicone resin of adhesive, use and have overall diameter and be 27mm, interior diameter is the rolled-up stock of the groove of 14mm, at room temperature, resulting powder is applied (15 tons/cm of 1.47GPa
2) pressure so that have the height 5mm, obtain the respective molded product thus.After molded, in Ar atmosphere, moulded product is heat-treated at 450 ℃.
Then, after resulting moulded product is carried out resin solidification, weight and size to moulded product are measured, and are to use the coil respectively have the suitable number of turns on the magnetic core respectively at moulded product then, make corresponding inductance component (each all as shown in Figure 2) thus.
Then, be inductance component at each resulting sample, powder filling rate (%) and magnetic permeability are measured.The result is shown in table 17.
Be appreciated that by table 17 by increasing the ratio of height to diameter of noncrystalline metal dust, the magnetic permeability of inductance component of the present invention is improved.On the other hand, be appreciated that and since when ratio of height to diameter above 2.0 the time, initial permeability is higher, but the magnetic permeability when DC stacked worsens, so the ratio of height to diameter of powder is preferably 2.0 or littler.
(example 137)
At first,, material is carried out weighing, to obtain composition F e as the powder production process
77P
10B
10Nb
2Cr
1Ti
0.1C
0.1Mn
0.1Cu
0.1, and, utilize said composition, use hydraulic atomized method to make to have the soft magnetic alloy powder of different medium particle diameters.
Then, as the moulded product production process, by utilizing various standard filter screens that resulting alloy powder is screened, make powder shown in table 18 thus, then will be as the silicone resin of adhesive amount and described powder with 3 quality %, overall diameter with 3.5 circles is 8mm then, interior diameter is 4mm, highly be 2mm coil together, described powder is placed the rolled-up stock of 10mm * 10mm, and described coil is provided so that the center that is positioned at moulded product after molded, at room temperature respectively described powder is applied with (5 tons/cm of 490MPa then
2) pressure therefore so that have the height of 4mm, obtain the respective molded product.Under 150 ℃, resulting moulded product is carried out resin solidification then.With regard to the condition of the 5th sample, equally also, make sample thus 450 ℃ of heat treatments of in nitrogen atmosphere, moulded product being carried out 0.5 hour.
Then, with regard to each resulting sample was inductance component, the peak value of the inductance value of 1MHz, crest frequency and Q can be tried to achieve the measurement that inductance and impedance are carried out under correspondent frequency by using LCR to measure meter.The result is shown in table 18.
Then, with regard to each sample inductance component, use common DC-DC converter evaluation kit (dc-dc converter evaluation kit) that power conversion efficient is measured.Measuring condition is input 12V, output 5V, driving frequency 300kHz, output current 1A.The result is also shown in table 18.
Shown in table 18, by filter screen particle diameter (sieve particle size) is made as 45 μ m or littler, and medium particle diameter is made as 30 μ m or littler, can make the Q crest frequency of inductance component of the present invention be 5000kHz or more than, the Q peak value be 40 or more than, make simultaneously power conversion efficient be 80% or more than, this is extraordinary.In addition, by the filter screen particle diameter being made as 45 μ m or littler, and medium particle diameter is made as 20 μ m or littler, can make the Q crest frequency be 1MHz or more than, the Q peak value be 50 or more than, in this case, power conversion efficient be 85% or more than, this is extraordinary.In addition, be appreciated that,, can further improve conversion efficiency by inductance component is heat-treated.
(example 138)
At first,, material is carried out weighing, to obtain composition F e as the powder production process
77P
10B
10Nb
2Cr
1Ti
0.1Mn
0.1Cu
0.1, and, utilize said composition, use hydraulic atomized method to make soft magnetic alloy powder.
Then, as the moulded product production process, by utilizing various standard filter screens that resulting alloy powder is screened, make powder shown in table 19 thus, to apply (5t/cm to described powder then as the silicone resin of adhesive amount and described powder then with 3 quality % with 490Mpa
2) pressure be 32mm so that form overall diameter, interior diameter is 20mm, highly is the annular of 5mm, makes the respective molded product thus.Under 150 ℃, resulting moulded product is carried out resin solidification.For relatively, adopt the sample of the powder that can make the Si that uses Fe-6.5 quality % in the same way.
Then, twining ten loop diameters around each sample that makes is 0.1mm, is covered with the copper cash of amide-imide (amide-imide) coating, makes inductance component thus.
Then, with regard to each resulting inductance component, can try to achieve the measurement that inductance and impedance are carried out at the correspondent frequency place by using LCR to measure meter at the peak value of inductance value, crest frequency and the Q at 10kHz place.The result is shown in table 19.
Then, with regard in these inductance components each, use common DC-DC converter evaluation kit that power conversion efficient is measured.Measuring condition is input 12V, output 5V, driving frequency 10kHz, output current 1A.The result is also shown in table 19.
(example 139 and 140)
Respectively material Fe, Fe-P, Fe-B, Fe-Cr, Fe-Nb, Ti, C, Mn and Cu are carried out weighing according to predetermined alloy composite, carrying out high-frequency heating with its fusing, make foundry alloy thus then through in the Ar atmosphere pressure-reducing chamber of finding time.Afterwards, utilize prepared foundry alloy, use single-roller method to make the band that thickness is 20 μ m.
The band of each 20 μ m all is formed the magnetic core of winding, and the stacked part of magnetic core is by inserting the bonded and insulation of therebetween silicone resin, then by the impedance analysis device to measuring at the initial permeability at 1kHz place.In this case, under room temperature, 250 ℃, 300 ℃, 400 ℃, 450 ℃ and 550 ℃, in Ar atmosphere, each sample carried out 5 minutes heat treatment respectively.
Shown in table 20, when heat-treating in Curie temperature or above and crystallization temperature or following temperature range, example 139 of the present invention and 140 alloy composite can present extraordinary soft magnet performance.Especially when in crystallization temperature or when above, soft magnet performance worsens rapidly.
Commercial Application
As mentioned above, use noncrystalline soft magnetic metallic material low cost to obtain high frequency magnetic core of the present invention with high saturation magnetic flux metric density and high resistivity.In addition, very good by the high frequency band magnetic property that coil is applied to the inductance component that forms on the described high frequency magnetic core, this never occurs under conventional situation.Therefore can low-cost make the dust core of high-performance high magnetic permeability, this never occurs under conventional situation.High frequency magnetic core of the present invention be suitable for various electronic equipments such as choke coil and power of transformer parts.
In addition, the high frequency magnetic core of the present invention that is made of the powder of fine particle size can realize making the high-performance inductance component that is used for high frequency.Can also realize in addition by the high frequency magnetic core that the fine particle size powder constitutes, carry out compression forming by enclosing at winding around under the state in the magnet, thereby magnet and winding around are integrated, make small size thus but be suitable for the inductance component of big electric current.Therefore high frequency magnetic core of the present invention is suitable for the inductance component of choke coil, transformer etc.
Table 1
| Alloy composite atom % | Band 200 μ m | Tc ℃ | T ℃ | Tx ℃ | Tx-Tg ℃ | Bs T | Initial permeability 1kHz | |
| Comparative example 1 | Fe 78P 0B 18Mo 4 | Crystalline phase | 262 | 490 | 514 | 24 | 1.27 | 4000 |
| Example 1 | Fe 78P 2B 16Mo 4 | Amorphous phase | 261 | 485 | 514 | 29 | 1.29 | 8000 |
| Example 2 | Fe 78P 8B 10Mo 4 | Amorphous phase | 256 | 466 | 506 | 40 | 1.28 | 15000 |
| Example 3 | Fe 78P 16B 2Mo 4 | Amorphous phase | 250 | 456 | 496 | 40 | 1.27 | 12000 |
| Comparative example 2 | Fe 78P 18B 0Mo 4 | Crystalline phase | 250 | - | 490 | - | 1.25 | 3500 |
| Comparative example 3 | Fe 82P 8B 10Mo 0 | Crystalline phase | 342 | 440 | 458 | 18 | 1.61 | 4000 |
| Example 4 | Fe 81P 8B 10Mo 0 | Amorphous phase | 318 | 446 | 477 | 31 | 1.53 | 5500 |
| Example 5 | Fe 78P 8B 10Mo 4 | Amorphous phase | 256 | 466 | 506 | 40 | 1.28 | 15000 |
| Example 6 | Fe 78P 8B 10Mo 5 | Amorphous phase | 242 | 480 | 520 | 40 | 1.20 | 14000 |
| Example 7 | Fe 72P 8B 10Mo 10 | Amorphous phase | 178 | 513 | 538 | 25 | 0.76 | 6000 |
| Comparative example 4 | Fe 70P 8B 10Mo 12 | Crystalline phase | 162 | - | 552 | - | 0.44 | 4500 |
| Example 8 | Fe 78P 8B 10A l4 | Amorphous phase | 365 | 456 | 487 | 31 | 1.53 | 7000 |
| Example 9 | Fe 78P 8B 10V 4 | Amorphous phase | 260 | 463 | 495 | 32 | 1.36 | 8000 |
| Example 10 | Fe 78P 8B 10Cr 4 | Amorphous phase | 259 | 454 | 480 | 26 | 1.31 | 7000 |
| Example 11 | Fe 78P 8B 10Y 4 | Amorphous phase | 292 | 482 | 507 | 25 | 1.29 | 6000 |
| Example 12 | Fe 78P 8B 10Zr 4 | Amorphous phase | 259 | 470 | 502 | 32 | 1.28 | 9000 |
| Example 13 | Fe 78P 8B 10Nb 4 | Amorphous phase | 258 | 476 | 516 | 40 | 1.27 | 17000 |
| Example 14 | Fe 78P 8B 10Ta 4 | Amorphous phase | 252 | 504 | 546 | 42 | 1.25 | 15000 |
| Example 15 | Fe 78P 8B 10W 4 | Amorphous phase | 246 | 486 | 529 | 43 | 1.23 | 13000 |
| Comparative example 5 | METGLAS | Crystalline phase | 400 | - | 525 | - | 1.58 | 4000 |
Table 2
| Alloy composite atom % | Band 200 μ m | Tc ℃ | Tg ℃ | Tx ℃ | Tx-Tg ℃ | Bs T | Initial permeability 1kHz | |
| Example 16 | Fe 78P 8B 10Si 0Mo 4 | Amorphous phase | 255 | 466 | 506 | 40 | 1.28 | 15000 |
| Example 17 | Fe 78P 7B 9Si 2Mo 4 | Amorphous phase | 257 | 472 | 508 | 36 | 1.27 | 13000 |
| Example 18 | Fe 78P 3B 9Si 8Mo 4 | Amorphous phase | 262 | 489 | 509 | 20 | 1.27 | 9000 |
| Comparative example 6 | Fe 78P 2B 8Si 10Mo 4 | Amorphous phase | 262 | - | 522 | - | 1.26 | 4500 |
| Example 19 | Fe 78P 7B 9Si 2Al 4 | Amorphous phase | 367 | 464 | 497 | 33 | 1.55 | 8000 |
| Example 20 | Fe 78P 7B 9Si 2V 4 | Amorphous phase | 265 | 467 | 505 | 38 | 1.39 | 7500 |
| Example 21 | Fe 78P 7B 9Si 2Cr 4 | Amorphous phase | 262 | 466 | 501 | 35 | 1.30 | 6500 |
| Example 22 | Fe 78P 7B 9Si 2Nb 4 | Amorphous phase | 262 | 480 | 518 | 38 | 1.24 | 14000 |
| Example 23 | Fe 78P 7B 9Si 2Ta 4 | Amorphous phase | 253 | 485 | 522 | 37 | 1.22 | 12000 |
| Example 24 | Fe 78P 7B 9Si 2W 4 | Amorphous phase | 249 | 497 | 541 | 44 | 1.20 | 11000 |
Table 3
| Alloy composite atom % | Band 200 μ m | Tc ℃ | Tg ℃ | Tx ℃ | Tx-Tg ℃ | Bs T | Initial permeability 1kHz | |
| Example 25 | (Fe 1.0Co 0.0) 78P 8B 10Mo 4 | Amorphous phase | 255 | 466 | 506 | 40 | 1.28 | 15000 |
| Example 26 | (Fe 0.8Co 0.2) 78P 8B 10Mo 4 | Amorphous phase | 278 | 468 | 510 | 42 | 1.28 | 14000 |
| Example 27 | (Fe 0.8Ni 0.2) 78P 8B 10Mo 4 | Amorphous phase | 251 | 462 | 511 | 49 | 1.20 | 16000 |
| Example 28 | (Fe 0.1Co 0.9) 78P 8B 10Mo 4 | Amorphous phase | 243 | 470 | 512 | 42 | 0.45 | 40000 |
| Example 29 | (Fe 0.05Ni 0.05Co 0.9) 78P 8B 10Mo 4 | Amorphous phase | 245 | 469 | 508 | 39 | 0.41 | 68000 |
| Comparative example 7 | (Fe 0.9Ni 1.0) 78P 8B 10Mo 4 | Amorphous phase | - | 460 | 508 | 48 | 0 | - |
Table 4
| Alloy composite atom % | Band 200 μ m | Tc ℃ | Tg ℃ | Tx ℃ | Tx-Tg ℃ | Bs T | Initial permeability 1kHz | |
| Example 30 | (Fe 1.0Co 0.0) 78P 7B 9Si 2Mo 4 | Amorphous phase | 257 | 472 | 508 | 36 | 1.27 | 13000 |
| Example 31 | (Fe 0.8Co 0.2) 78P 7B 9Si 2Mo 4 | Amorphous phase | 281 | 474 | 510 | 36 | 1.28 | 6500 |
| Example 32 | (Fe 0.8Ni 0.2) 78P 7B 9Si 2Mo 4 | Amorphous phase | 250 | 466 | 513 | 47 | 1.17 | 10000 |
| Example 33 | (Fe 0.05Ni 0.05Co 0.9) 78P 7B 9Si 2Mo 4 | Amorphous phase | 245 | 478 | 517 | 39 | 0.41 | 70000 |
| Comparative example 8 | (Fe 0.0Ni 1.0) 78P 7B 9Si 2Mo 4 | Amorphous phase | 246 | 455 | 493 | 38 | 0 | - |
Table 5
| Alloy composite atom % | Powder-200 μ m | |
| Example 34 | Fe 78P 6B 12Mo 4 | Amorphous phase |
| Example 35 | Fe 78P 6B 12Al 4 | Amorphous phase |
| Example 36 | Fe 78P 6B 12Nb 4 | Amorphous phase |
| Comparative example 9 | METGLAS | Crystalline phase |
Table 6-1
| Alloy composite atom % | Additive weight % | Band 200 μ m | Tc ℃ | Tg ℃ | Tx ℃ | Tx-Tg ℃ | Bs T | Initial permeability 1kHz | ||
| Example 37 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0C 0Mn 0Cu 0 | Amorphous phase | 280 | 480 | 514 | 34 | 1.31 | 12500 | |
| Example 38 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 278 | 481 | 517 | 36 | 1.30 | 10500 | |
| Comparative example 10 | Fe 77P 1B 19Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Crystalline phase | 285 | 525 | 543 | 18 | 1.35 | 4000 | |
| Example 39 | Fe 77P 2B 18Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 285 | 518 | 539 | 21 | 1.33 | 6500 | |
| Example 40 | Fe 77P 18B 2Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 242 | 452 | 474 | 22 | 1.25 | 5500 | |
| Comparative example 11 | Fe 77P 19B 1Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Crystalline phase | 234 | 442 | 458 | 16 | 1.24 | 4500 | |
| Example 41 | Fe 69P 10B 10Nb 10Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 168 | 517 | 548 | 22 | 0.70 | 5000 | |
| Comparative example 12 | Fe 68P 10B 10Nb 11Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Crystalline phase | 154 | 522 | 550 | 18 | 0.45 | 4000 | |
| Example 42 | Fe 77P 6B 6Si 8b 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 283 | 519 | 533 | 24 | 1.34 | 8000 | |
| Comparative example 13 | Fe 77P 5B 5Si 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Crystalline phase | 287 | - | 555 | 19 | 1.34 | 5500 | |
| Example 43 | Fe 77P 10B 10Nb 2Al 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 266 | 476 | 502 | 26 | 1.43 | 8600 | |
| Example 44 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 252 | 485 | 514 | 29 | 1.33 | 11000 | |
| Example 45 | Fe 77P 10B 10Mo 2A1 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 258 | 482 | 516 | 34 | 1.39 | 9500 | |
| Example 46 | Fe 77P 10B 10Mo 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 245 | 489 | 524 | 35 | 1.28 | 11500 | |
| Example 47 | Fe 77P 10B 10Al 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 315 | 468 | 491 | 23 | 1.52 | 6500 | |
| Example 48 | Fe 77P 10B 10V 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 260 | 470 | 495 | 25 | 1.35 | 6000 | |
| Example 49 | Fe 77P 10B 10Y 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 271 | 483 | 513 | 30 | 1.37 | 7500 | |
| Example 50 | Fe 77P 10B 10Zr 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 267 | 482 | 508 | 26 | 1.36 | 8500 | |
| Example 51 | Fe 77P 10B 10Ta 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 251 | 486 | 524 | 28 | 1.32 | 10500 | |
| Example 52 | Fe 77P 10B 10W 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 243 | 490 | 527 | 37 | 1.28 | 9500 | |
| Comparative example 14 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.4C 0.1Mn 0.1Cu 0.1 | Crystalline phase | 272 | 483 | 502 | 19 | 1.28 | 6000 | |
| Example 53 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.3Mn 0.1Cu 0.1 | Amorphous phase | 288 | 482 | 515 | 33 | 1.32 | 7000 | |
| Example 54 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.5Mn 0.1Cu 0.1 | Amorphous phase | 295 | 482 | 504 | 22 | 1.32 | 5500 | |
Table 6-2
| Alloy composite atom % | Additive weight % | Band 200 μ m | Tc ℃ | Tg ℃ | Tx ℃ | Tx-Tg ℃ | Bs T | Initial permeability 1kHz | |
| Comparative example 15 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.6Mn 0.1Cu 0.1 | Crystalline phase | 301 | 486 | 498 | 12 | 1.35 | 4000 |
| Example 55 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 1.0Cu 0.1 | Amorphous phase | 263 | 481 | 517 | 36 | 1.26 | 12000 |
| Example 56 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 2.0Cu 0.1 | Amorphous phase | 248 | 481 | 516 | 35 | 1.20 | 12500 |
| Comparative example 16 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 3.0Cu 0.1 | Amorphous phase | 229 | 479 | 515 | 36 | 1.11 | 10000 |
| Example 57 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.5 | Amorphous phase | 281 | 480 | 515 | 35 | 1.30 | 7000 |
| Example 58 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 1.0 | Amorphous phase | 280 | 481 | 511 | 30 | 1.28 | 5500 |
| Comparative example 17 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 1.2 | Crystalline phase | 285 | 480 | 492 | 12 | 1.29 | 4500 |
| Example 59 | (Fe 0.8Co 0.2) 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 290 | 479 | 508 | 29 | 1.34 | 12000 |
| Comparative example 18 | (Fe 0.8Ni 0.2) 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 265 | 476 | 516 | 40 | 1.34 | 13500 |
| Example 60 | (Fe 0.1Co 0.8) 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | 262 | 482 | 508 | 26 | 0.63 | 60000 |
| Comparative example 19 | (Fe 0.0Ni 1.0) 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase | - | 465 | 509 | 44 | - | - |
| Comparative example 20 | Metal glass METGLAS | Crystalline phase | 400 | - | 525 | - | 1.58 | 4000 |
Table 7
| Alloy composite atom % | Additive weight % | Rate of corrosion 1 standard NaClmm/ | |
| Example 61 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0C 0Mn 0Cu 0 | 0.28 |
| Example 62 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.22 |
| Example 63 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.3C 0.1Mn 0.1Cu 0.1 | 0.18 |
| Example 64 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.5C 0.1Mn 0.1Cu 0.1 | 0.12 |
| Example 65 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 1.0Cu 0.1 | 0.20 |
| Example 66 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 2.0Cu 0.1 | 0.16 |
| Example 67 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 3.0Cu 0.1 | 0.15 |
| Example 68 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.5 | 0.11 |
| Example 69 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 1.0 | 0.06 |
| Example 70 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 1.5 | 0.04 |
| Comparative example 21 | METGLAS | 2.7 |
Table 8
| Alloy composite atom % | Additive weight % | Thickness μ m | The magnetic permeability 50kHz of toroidal core | |
| Example 71 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 20 | 9800 |
| Example 72 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.5 | 20 | 10000 |
| Example 73 | Fe 77P 7B 13Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 20 | 11300 |
| Comparative example 22 | | 20 | 4000 |
Table 9
| Alloy composite atom % | Additive weight % | Thickness μ m | The L μ H 50kHz of lamination magnetic core | The Q 50kHz of lamination magnetic core | |
| Example 74 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 20 | 42 | 52 |
| Example 75 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 105 | 29 | 32 |
| Example 76 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 150 | 28 | 28 |
| Comparative example 23 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 170 | 19 | 25 |
| Example 77 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.3Mn 0.1Cu 0.1 | 20 | 41 | 49 |
| Example 78 | Fe 77P 7B 13Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 25 | 38 | 58 |
| Comparative example 24 | | 20 | 20 | 26 |
Table 10
| Alloy composite atom % | Additive weight % | Powder-200 μ m | |
| Example 79 | Fe 77P 7B 13Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase |
| Example 80 | Fe 77P 9B 11Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase |
| Example 81 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase |
| Example 82 | Fe 77P 11B 9Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | Amorphous phase |
| Comparative example 25 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.7Mn 0.1Cu 0.1 | Crystalline phase |
| Comparative example 26 | Glass metal | Crystalline phase |
Table 11
| Alloy composite atom % | Additive weight % | Initial permeability 50kHz | Loss mW/cc 50kHz-300mT | Density % | |
| Example 83 | Fe 77P 7B 13Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 26 | 760 | 74 |
| Example 84 | Fe 77P 9B 11Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 25 | 820 | 73 |
| Example 85 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 26 | 860 | 73 |
| Example 86 | Fe 77P 11B 9Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 27 | 920 | 74 |
| Comparative example 26 | Fe | 18 | 6320 | 85 | |
| Comparative example 27 | Fe-Si-Cr | 26 | 2850 | 82 | |
| Comparative example 28 | Sendust | 24 | 2200 | 78 |
Table 12-1
| Alloy composite atom % | Magnetic density/T is 1.6 * 10 4The A/m place | Initial permeability is at the 100kHz place | The XRD measurement result | |
| Comparative example 30 | Fe 79P 1B 16Mo 4 | 0.64 | 25 | Crystalline phase |
| Example 86 | Fe 78P 2B 16Mo 4 | 0.63 | 30 | Amorphous phase |
| Example 87 | Fe 75P 16B 5Mo 4 | 0.60 | 30 | Amorphous phase |
| Comparative example 31 | Fe 74P 17B 5Mo 4 | 0.59 | 24 | Crystalline phase |
| Comparative example 32 | Fe 79P 16B 1Mo 4 | 0.63 | 20 | Crystalline phase |
| Example 88 | Fe 78P 16B 2Mo 4 | 0.62 | 32 | Amorphous phase |
| Example 89 | Fe 75P 5B 16Mo 4 | 0.59 | 30 | Amorphous phase |
| Comparative example 33 | Fe 74P 5B 17Mo 4 | 0.58 | 25 | Crystalline phase |
| Comparative example 34 | Fe 82P 8B 10Mo 0 | 0.79 | 24 | Crystalline phase |
| Example 90 | Fe 81P 8B 10Mo 1 | 0.75 | 30 | Amorphous phase |
| Example 91 | Fe 78P 8B 10Mo 4 | 0.62 | 32 | Amorphous phase |
| Example 92 | Fe 72P 8B 10Mo 10 | 0.37 | 30 | Amorphous phase |
| Comparative example 35 | Fe 71P 8B 10Mo 11 | 0.30 | 25 | Crystalline phase |
| Example 93 | Fe 78P 7B 9Mo 4Si 2 | 0.62 | 32 | Amorphous phase |
| Example 94 | Fe 72P 7B 9Mo 4Si 8 | 0.55 | 30 | Amorphous phase |
| Comparative example 36 | Fe 71P 7B 9Mo 4Si 9 | 0.53 | 24 | Crystalline phase |
| Example 95 | Fe 72P 8B 10Al 4 | 0.75 | 30 | Amorphous phase |
| Example 96 | Fe 78P 8B 10V 4 | 0.67 | 31 | Amorphous phase |
| Example 97 | Fe 78P 8B 10Cr 4 | 0.64 | 30 | Amorphous phase |
| Example 98 | Fe 78P 8B 10Y 4 | 0.63 | 30 | Amorphous phase |
| Example 99 | Fe 78P 8B 10Zr 4 | 0.63 | 31 | Amorphous phase |
| Example 100 | Fe 78P 8B 10Nb 4 | 0.62 | 32 | Amorphous phase |
| Example 101 | Fe 78P 8B 10Ta 4 | 0.61 | 32 | Amorphous phase |
| Example 102 | Fe 78P 8B 10W 4 | 0.60 | 31 | Amorphous phase |
Table 12-2
| Alloy composite atom % | Magnetic density/T is 1.6 * 10 4The A/m place | Initial permeability is at the 100kHa place | The XRD measurement result | |
| Example 103 | (Fe 0.8Co 0.2) 78P 8B 10Mo 4 | 0.63 | 31 | Amorphous state |
| Example 104 | (Fe 0.8Ni 0.2) 78P 8B 10Mo 4 | 0.59 | 32 | Amorphous state |
| Example 105 | (Fe 0.1Co 0.9) 78P 8B 10Mo 4 | 0.22 | 34 | Amorphous state |
| Example 106 | (Fe 0.05Ni 0.05Co 0.9) 78P 8B 10Mo 4 | 0.20 | 37 | Amorphous state |
| Comparative example 37 | (Fe 0.0Ni 1.0) 78P 8B 10Mo 4 | 0 | - | Amorphous state |
| Example 107 | (Fe 0.8Co 0.2) 78P 7B 9Si 2Mo 4 | 0.63 | 30 | Amorphous state |
| Example 108 | (Fe 0.8Ni 0.2) 78P 7B 9Si 2Mo 4 | 0.57 | 32 | Amorphous state |
| Example 109 | (Fe 0.05Ni 0.05Co 0.9) 78P 7B 9Si 2Mo 4 | 0.20 | 37 | Amorphous state |
| Comparative example 38 | (Fe 0.0Ni 1.0) 78P 7B 9Si 2Mo 4 | 0 | - | Amorphous state |
Table 13-1
| Alloy composite atom % | Additive weight % | Magnetic density/T is locating 1.6 * 10 4A/m | Initial permeability is at the 100kHz place | The XRD measurement result | |
| Example 110 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0C 0Mn 0Cu 0 | 0.49 | 32 | Amorphous phase |
| Example 111 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.49 | 32 | Amorphous phase |
| Comparative example 39 | Fe 81P 1B 15Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.50 | 20 | Crystalline phase |
| Example 112 | Fe 80P 2B 15Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.50 | 30 | Amorphous phase |
| Example 113 | Fe 75P 18B 4Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.48 | 30 | Amorphous phase |
| Comparative example 40 | Fe 74P 19B 4Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.47 | 24 | Crystalline phase |
| Comparative example 41 | Fe 81P 15B 1Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.50 | 20 | Crystalline phase |
| Example 114 | Fe 80P 15B 2Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.50 | 30 | Amorphous phase |
| Example 115 | Fe 75P 4B 18Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.47 | 32 | Amorphous phase |
| Comparative example 42 | Fe 74P 4B 19Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.47 | 22 | Crystalline phase |
| Comparative example 43 | Fe 79.5P 10B 10Nb 0.5Cr 0 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.57 | 20 | Crystalline phase |
| Example 116 | Fe 78P 10B 10Nb 1Cr 0 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.55 | 30 | Amorphous phase |
| Example 117 | Fe 78P 10B 10Nb 2Cr 0 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.53 | 32 | Amorphous phase |
| Example 118 | Fe 75P 10B 10Nb 4Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.45 | 32 | Amorphous phase |
| Example 119 | Fe 74P 10B 10Nb 5Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.42 | 31 | Amorphous phase |
| Comparative example 44 | Fe 73P 10B 10Nb 6Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.38 | 24 | Crystalline phase |
| Example 120 | Fe 73P 10B 10Si 4Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.47 | 30 | Amorphous phase |
| Comparative example 45 | Fe 72P 10B 10Si 5Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.46 | 24 | Crystalline phase |
| Comparative example 46 | Fe 83P 7B 7Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.50 | 19 | Crystalline phase |
Table 13-2
| Alloy composite atom % | Additive weight % | Magnetic density/T is 1.6 * 10 4The A/m place | Initial permeability is at the 100kHz place | The XRD measurement result | |
| Example 121 | Fe 82P 7.5B 7.5Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.50 | 30 | Amorphous phase |
| Example 122 | Fe 74P 11.5B 11.5Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.48 | 31 | Amorphous phase |
| Comparative example 47 | Fe 73P 12B 12Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.46 | 24 | Crystalline phase |
| Example 123 | Fe 73P 10B 10Nb 2Cr 1 | Ti 0.3C 0.1Mn 0.1Cu 0.1 | 0.48 | 30 | Amorphous phase |
| Comparative example 48 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.4C 0.1Mn 0.1Cu 0.1 | 0.48 | 24 | Crystalline phase |
| Example 124 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.3Mn 0.1Cu 0.1 | 0.50 | 31 | Amorphous phase |
| Example 125 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.6Mn 0.1Cu 0.1 | 0.50 | 30 | Amorphous phase |
| Comparative example 49 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.6Mn 0.1Cu 0.1 | 0.51 | 24 | Crystalline phase |
| Example 126 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 1.0Cu 0.1 | 0.47 | 31 | Amorphous phase |
| Example 127 | Fe 77P 10B 10nb 2Cr 1 | Ti 0.1C 0.1Mn 2.0Cu 0.1 | 0.45 | 32 | Amorphous phase |
| Comparative example 50 | Fe 77P 10B 10nb 2Cr 1 | Ti 0.1C 0.1Mn 3.0Cu 0.1 | 0.42 | 24 | Crystalline phase |
| Example 128 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.5 | 0.49 | 31 | Amorphous phase |
| Example 129 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 1.0 | 0.48 | 30 | Amorphous phase |
| Comparative example 51 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 1.2 | 0.48 | 24 | Crystalline phase |
| Example 130 | (Fe 0.7Co 0.3) 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.50 | 32 | Amorphous phase |
| Comparative example 52 | (Fe 0.6Co 0.4) 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.50 | 23 | Crystalline phase |
| Example 131 | (Fe 0.7Ni 0.3) 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.45 | 31 | Amorphous phase |
| Comparative example 53 | (Fe 0.6Ni 0.4) 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 0.42 | 24 | Crystalline phase |
Table 14
| Sample number into spectrum | Amount of resin | Molding temperature | Powder filling rate % | Magnetic density/T is 1.6 * 10 4The A/m place | Resistivity Ω cm |
| 1 | 0.5％ | Room temperature | 68.1 | 0.44 | ≥100 |
| 2 | 1.0％ | Room temperature | 69.9 | 0.45 | ≥100 |
| 3 | 2.5％ | Room temperature | 72.7 | 0.47 | ≥100 |
| 4 | 5.0％ | Room temperature | 71.5 | 0.46 | ≥100 |
| 5 | 0.5％ | 150℃ | 80.3 | 0.73 | 5 |
| 6 | 1.0％ | 150℃ | 81.9 | 0.75 | 10 |
| 7 | 2.5％ | 150℃ | 82.6 | 0.75 | 15 |
| 8 | 5.0％ | 150℃ | 72.7 | 0.47 | ≥100 |
| 9 | 0.5％ | 480℃ | 95.2 | 1.13 | 0.1 |
| 10 | 1.0％ | 480℃ | 92.4 | 1.09 | 0.5 |
| 11 | 2.5％ | 480℃ | 83.0 | 0.76 | 10 |
| 12 | 5.0％ | 480℃ | 73.4 | 0.48 | ≥100 |
Table 15
| The sample title | Magnetic density/T is 1.6 * 10 4The A/m place | Resistivity Ω cm | Magnetic permeability | Core loss 20kHz 0.1T |
| The present invention | 10,900 | 0.5 | 150 | 60mW/cc |
| The present invention's (heat treatment) | 11,100 | 0.5 | 200 | 20 |
| The MnZn ferrite | 5,500 | ≥10E4 | 100 * | 8 |
| Sendust | 6,500 | 100 | 80 | 90 |
| 6.5% silicon steel | 10,000 | 100μ | 100 * | 250 |
| The base amorphous phase material of Fe | 13,000 | 150μ | 100 * | 400 |
* owing on the part magnetic circuit, form the power specification of breach
Table 16
| Sample number into spectrum | Alloy composite | The powder ratio % that adds | Powder filling rate % | Magnetic permeability is at the 100kHz place | Core loss 20kHz 0.1T |
| Comparative example 54 | - | - | 74.5 | 34 | 20kW/m 3 |
| 1 | 3％SiFe | 5 | 75.1 | 37 | 25 |
| 2 | 3 | 10 | 75.7 | 39 | 35 |
| 3 | 3 | 20 | 76.3 | 40 | 55 |
| 4 | 3 | 30 | 76.9 | 41 | 65 |
| 5 | 3 | 40 | 77.5 | 42 | 75 |
| 6 | 3％SiFe | 50 | 78.0 | 44 | 85 |
| 7 | 3％SiFe | 60 | 78.2 | 44 | 190 |
| 8 | | 30 | 75.7 | 38 | 75 |
| 9 | The | 30 | 78.0 | 43 | 80 |
| 10 | | 30 | 79.5 | 48 | 90 |
Table 17
| Ratio of height to diameter | Powder filling rate % | Magnetic permeability during 100kHz | |
| Locate at 0 (Oe) | Locate at 50 (Oe) | ||
| 1.1 | 73 | 32 | 30 |
| 1.3 | 71 | 35 | 30 |
| 1.5 | 70 | 37 | 31 |
| 1.9 | 69 | 42 | 31 |
| 2.2 | 68 | 47 | 29 |
Table 18
| Sample number into spectrum | Filter screen particle diameter μ m | Medium particle diameter (D50) μ m | L (μ H) is at the 1MHz place | The crest frequency of Q | The peak value of Q | Power conversion efficient |
| Comparative example 55 | 45 | 34 | 0.60 | 300kHz | 31 | 79.8％ |
| 1 | 45 | 29 | 0.63 | 600kHz | 43 | 83.3 |
| 2 | 45 | 24 | 0.66 | 800kHz | 46 | 83.9 |
| 3 | 45 | 19 | 0.69 | 1.5MHz | 61 | 85.5 |
| 4 | 45 | 16 | 0.67 | 2.5MHz | 66 | 85.6 |
| 5 | 45 | 12 | 0.65 | 3.5MHz | 75 | 85.9 |
| 5 (heat treatments) | 45 | 12 | 0.75 | 3.0MHz | 81 | 87.6 |
| Comparative example 56 | 63 | 28 | 0.69 | 400kHz | 33 | 79.5 |
Table 19
| Sample number into spectrum | The powder composition | The filter screen grain is through μ m | Medium particle diameter (D50) μ m | The 10kHz that L (μ H) locates | The crest frequency of Q (kHz) | The peak value of Q | Power conversion efficient (%) |
| 1 | Fe 77P 10B 10Nb 2Cr 1Ti 0.1Mn 0.1Cu 0.1 | 250 | 192 | 1.63 | 50 | 20 | 85.2 |
| 2 | Fe 77P 10B 10Nb 2Cr 1Ti 0.1Mn 0.1Cu 0.1 | 150 | 96 | 1.58 | 100 | 26 | 85.4 |
| 3 | Fe 77P 10B 10Nb 2Cr 1Ti 0.1Mn 0.1Cu 0.1 | 45 | 28 | 1.14 | 600 | 43 | 82.8 |
| Comparative example 57 | Fe-6.5wt％Si | 150 | 92 | 1.72 | 100 | 18 | 82.1 |
Table 20
| Alloy composite atom % | Additive weight % | Tc ℃ | When under corresponding temperature, heat-treating at the initial permeability at 1kHz place | |||||||
| Room temperature | 250℃ | 300℃ | 400℃ | 450℃ | 500℃ | 550℃ | ||||
| Example 139 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0C 0Mn 0Cu 0 | 280 | 700 | 1000 | 9000 | 11000 | 12000 | 8000 | 120 |
| Example 140 | Fe 77P 10B 10Nb 2Cr 1 | Ti 0.1C 0.1Mn 0.1Cu 0.1 | 278 | 600 | 800 | 8000 | 9500 | 10000 | 6000 | 80 |
Claims (77)
1. amorphous soft magnetic, the expression formula of its composition is (Fe
1-αTM
α)
100-w-x-y-zP
wB
xL
ySi
zWherein contain unavoidable impurities, TM is choose from Co and Ni at least a, L is choose from the group that is made of Al, V, Cr, Y, Zr, Mo, Nb, Ta and W at least a, 0≤α≤0.98,2 atom %≤w≤16 atom %, 2 atom %≤x≤16 atom %, 0 atom %＜y≤10 atom % and 0 atom %≤z≤8 atom %.
2. amorphous soft magnetic as claimed in claim 1, wherein crystallization start temperature (Tx) is 550 ℃ or lower, and glass transition temperature (Tg) is 520 ℃ or lower, and the supercooled liquid scope of being represented by Δ Tx=Tx-Tg is 20 ℃ or bigger.
3. amorphous soft magnetic as claimed in claim 1, wherein saturation flux density is 1.2T or bigger.
4. amorphous soft magnetic as claimed in claim 1, wherein Curie temperature is 240 ℃ or higher.
5. amorphous soft magnetic element that is made by amorphous soft magnetic as claimed in claim 1, the thickness of wherein said amorphous soft magnetic element is 0.5mm or thicker, and cross-sectional area is 0.15mm
2Or it is bigger.
6. amorphous soft magnetic band that is made by amorphous soft magnetic as claimed in claim 1, the thickness of wherein said amorphous soft magnetic band is 1 to 200 μ m.
7. amorphous soft magnetic band as claimed in claim 6, wherein said amorphous soft magnetic band frequency be the magnetic permeability of 1kHz be 5000 or more than.
8. amorphous soft magnetic powder of being made by amorphous soft magnetic as claimed in claim 1, wherein said amorphous soft magnetic particles of powder size is 200 μ m or following, except zero.
9. amorphous soft magnetic powder as claimed in claim 8, wherein said amorphous soft magnetic powder contain the amorphous soft magnetic powder that makes by water atomization and the amorphous soft magnetic powder that makes by aerosolization at least a, and the particle size of 50% or higher quantity of described powder particle is greater than 3 μ m.
10. amorphous soft magnetic powder as claimed in claim 8, wherein said amorphous soft magnetic powder contain the amorphous soft magnetic powder that makes by water atomization and the amorphous soft magnetic powder that makes by aerosolization at least a, making described amorphous soft magnetic powder is the filter screen of 250 μ m by mesh size, and the central diameter of its particle size is 200 μ m or littler.
11. amorphous soft magnetic powder as claimed in claim 8, wherein said amorphous soft magnetic powder contain the amorphous soft magnetic powder that makes by water atomization and the amorphous soft magnetic powder that makes by aerosolization at least a, making described amorphous soft magnetic powder is the filter screen of 150 μ m by mesh size, and to make the central diameter of its particle size be 100 μ m or littler.
12. amorphous soft magnetic powder as claimed in claim 8, wherein said amorphous soft magnetic powder contain the amorphous soft magnetic powder that makes by water atomization and the amorphous soft magnetic powder that makes by aerosolization at least a, making described amorphous soft magnetic powder is the filter screen of 45 μ m by mesh size, and to make the central diameter of its particle size be 30 μ m or littler.
13. amorphous soft magnetic powder as claimed in claim 8, wherein said amorphous soft magnetic powder contain the amorphous soft magnetic powder that makes by water atomization and the amorphous soft magnetic powder that makes by aerosolization at least a, making described amorphous soft magnetic powder is the filter screen of 45 μ m by mesh size, and to make the central diameter of its particle size be 20 μ m or littler.
14. amorphous soft magnetic powder as claimed in claim 8, the ratio of height to diameter of wherein said amorphous soft magnetic powder are 1 to 2.
15. one kind by processing the magnetic core that forms to amorphous soft magnetic element as claimed in claim 5.
16. one kind by carrying out the magnetic core that the annular winding forms to amorphous soft magnetic band as claimed in claim 6.
17. magnetic core as claimed in claim 16 carries out the annular winding by insulator to described amorphous soft magnetic band and forms.
18. one kind by carrying out the stacked magnetic core that forms with the multi-disc of described basic identical shape amorphous soft magnetic band as claimed in claim 6.
19. magnetic core as claimed in claim 18, it is by the described amorphous soft magnetic band of the multi-disc of described basic identical shape is carried out stacked formation via intervenient insulator.
20. one kind by carrying out the molded magnetic core that forms to the material powder that comprises amorphous soft magnetic powder as claimed in claim 8 with the mixture that 10 quality % or lower amount are added into adhesive wherein.
21. magnetic core as claimed in claim 20, the blending ratio of wherein said adhesive in described mixture are 5 quality % or still less, the activity coefficient of described material powder in described magnetic core be 70% or more than, when applying 1.6 * 10
4During the magnetic field of A/m magnetic density be 0.4T or more than, and resistivity is 1 Ω cm or bigger.
22. magnetic core as claimed in claim 20, the blending ratio of wherein said adhesive in described mixture is 3 quality % or still less, molding temperature is equal to or higher than the softening point of described adhesive, the activity coefficient of described material powder in described magnetic core be 80% or more than, when applying 1.6 * 10
4During the magnetic field of A/m magnetic density be 0.6T or more than, and resistivity is 0.1 Ω cm or bigger.
23. magnetic core as claimed in claim 20, the blending ratio of wherein said adhesive in described mixture is 1 quality % or still less, molding temperature is positioned at the supercooled liquid scope of described amorphous soft magnetic powder, the activity coefficient of described material powder in described magnetic core be 90% or more than, when applying 1.6 * 10
4During the magnetic field of A/m magnetic density be 0.9T or more than, and resistivity is 0.01 Ω cm or bigger.
24. magnetic core as claimed in claim 20, wherein said material powder contain the soft-magnetic alloy powder of 5 volume % to 50 volume %, compare with described amorphous soft magnetic powder, the medium particle diameter of described soft-magnetic alloy powder is less and hardness is lower.
25. magnetic core as claimed in claim 15, wherein said magnetic core forms by heat-treating in the temperature range of Curie temperature that is equal to or higher than described amorphous soft magnetic and the crystallization onset temperature that is equal to or less than described amorphous soft magnetic.
26. one kind by using the inductance component that coil with at least one circle forms on magnetic core as claimed in claim 15.
27. one kind by carrying out the Unitarily molded inductance component that forms to magnetic core as claimed in claim 20 and coil, wherein said coil forms by twining at least one astragal shape conductor, and is placed in the described magnetic core.
28. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 10 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 10kHz or above frequency band be 20 or more than.
29. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 11 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 100kHz or above frequency band be 25 or more than.
30. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 12 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 500kHz or above frequency band be 40 or more than.
31. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 13 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 1MHz or above frequency band be 50 or more than.
32. inductance component as claimed in claim 28, wherein said coil forms by twining at least one astragal shape conductor, and is placed in the described magnetic core, and described magnetic core and described coil are integrally molded.
33. inductance component as claimed in claim 26, wherein said magnetic core is formed with breach.
34. magnetic core as claimed in claim 26, wherein said magnetic core forms by heat-treating in the temperature range of Curie temperature that is equal to or higher than described amorphous soft magnetic and the crystallization onset temperature that is equal to or less than described amorphous soft magnetic.
35. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 14 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 10kHz or above frequency band be 20 or more than.
36. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 14 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 100kHz or above frequency band be 25 or more than.
37. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 14 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 500kHz or above frequency band be 40 or more than.
38. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 14 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 1MHz or above frequency band be 50 or more than.
39. inductance component as claimed in claim 35, wherein said coil forms by twining at least one astragal shape conductor, and is placed in the described magnetic core, and described magnetic core and described coil are integrally molded.
40. an amorphous soft magnetic, the expression formula of its composition are (Fe
1-αTM
α)
100-w-x-y-zP
wB
xL
ySi
zTi
pC
qMn
rCu
sWherein contain unavoidable impurities, TM is choose from Co and Ni at least a, L is choose from the group that is made of Al, Cr, Zr, Mo and Nb at least a, 0≤α≤0.3,2 atom %≤w≤18 atom %, 2 atom %≤x≤5 atom %, 0 atom %＜y≤10 atom %, 0 atom %≤z≤4 atom %, wherein all to be illustrated in the gross mass of Fe, TM, P, B, L and Si be 100 o'clock interpolation ratio for each p, q, r and s, and be defined as 0≤p≤0.3,0≤q≤0.5,0≤r≤2,0≤s≤1.
41. amorphous soft magnetic as claimed in claim 40, wherein crystallization start temperature (Tx) is 550 ℃ or lower, and glass transition temperature (Tg) is 520 ℃ or lower, and is 20 ℃ or higher by the supercooled liquid scope that Δ Tx=Tx-Tg represents.
42. amorphous soft magnetic as claimed in claim 40, wherein saturation flux density is 1.2T or higher.
43. amorphous soft magnetic as claimed in claim 40, wherein Curie temperature is 240 ℃ or higher.
44. an amorphous soft magnetic element of being made by amorphous soft magnetic as claimed in claim 40, the thickness of wherein said amorphous soft magnetic element is 0.5mm or thicker, and cross-sectional area is 0.15mm
2Or it is bigger.
45. an amorphous soft magnetic band of being made by amorphous soft magnetic as claimed in claim 40, the thickness of wherein said amorphous soft magnetic band are 1 to 200 μ m.
46. amorphous soft magnetic band as claimed in claim 45, wherein said amorphous soft magnetic band are that the magnetic permeability of 1kHz is 5000 or higher in frequency.
47. an amorphous soft magnetic powder of being made by amorphous soft magnetic as claimed in claim 40, wherein said amorphous soft magnetic particles of powder size is 200 μ m or following, except zero.
48. amorphous soft magnetic powder as claimed in claim 47, wherein said amorphous soft magnetic powder contain the amorphous soft magnetic powder that makes by water atomization and the amorphous soft magnetic powder that makes by aerosolization at least a, and the granular size of 50% or above quantity of described powder particle is greater than 3 μ m.
49. amorphous soft magnetic powder as claimed in claim 47, wherein said amorphous soft magnetic powder contain the amorphous soft magnetic powder that makes by water atomization and the amorphous soft magnetic powder that makes by aerosolization at least a, making described amorphous soft magnetic powder is the filter screen of 250 μ m by mesh size, and to make the central diameter of its particle size be 200 μ m or littler.
50. amorphous soft magnetic powder as claimed in claim 47, wherein said amorphous soft magnetic powder contain the amorphous soft magnetic powder that makes by water atomization and the amorphous soft magnetic powder that makes by aerosolization at least a, making described amorphous soft magnetic powder is the filter screen of 150 μ m by mesh size, and to make the central diameter of its particle size be 100 μ m or littler.
51. amorphous soft magnetic powder as claimed in claim 47, wherein said amorphous soft magnetic powder contain the amorphous soft magnetic powder that makes by water atomization and the amorphous soft magnetic powder that makes by aerosolization at least a, making described amorphous soft magnetic powder is the filter screen of 45 μ m by mesh size, and to make the central diameter of its particle size be 30 μ m or littler.
52. amorphous soft magnetic powder as claimed in claim 47, wherein said amorphous soft magnetic powder contain the amorphous soft magnetic powder that makes by water atomization and the amorphous soft magnetic powder that makes by aerosolization at least a, making described amorphous soft magnetic powder is the filter screen of 45 μ m by mesh size, and to make the central diameter of its particle size be 20 μ m or littler.
53. amorphous soft magnetic powder as claimed in claim 47, the ratio of height to diameter of wherein said amorphous soft magnetic powder are 1 to 2.
54. one kind by processing the magnetic core that forms to amorphous soft magnetic element as claimed in claim 44.
55. one kind by carrying out the magnetic core that the annular winding forms to amorphous soft magnetic band as claimed in claim 45.
56. magnetic core as claimed in claim 55, it carries out the annular winding by insulator to described amorphous soft magnetic band and forms.
57. one kind by carrying out the stacked magnetic core that forms with the multi-disc of described basic identical shape amorphous soft magnetic band as claimed in claim 45.
58. magnetic core as claimed in claim 57, it is by carrying out stacked formation with the described amorphous soft magnetic band of the multi-disc of described basic identical shape via intervenient insulator.
59. one kind by carrying out the molded magnetic core that forms to the material powder that comprises amorphous soft magnetic powder as claimed in claim 47 with the mixture that 10 quality % or lower amount are added into adhesive wherein.
60. magnetic core as claimed in claim 59, the blending ratio of wherein said adhesive in described mixture are 5 quality % or still less, the activity coefficient of described material powder in described magnetic core be 70% or more than, when applying 1.6 * 10
4During the magnetic field of A/m magnetic density be 0.4T or more than, and resistivity is 1 Ω cm or bigger.
61. magnetic core as claimed in claim 59, the blending ratio of wherein said adhesive in described mixture is 3 quality % or still less, molding temperature is equal to or higher than the softening point of described adhesive, the activity coefficient of described material powder in described magnetic core be 80% or more than, when applying 1.6 * 10
4During the magnetic field of A/m magnetic density be 0.6T or more than, and resistivity is 0.1 Ω cm or bigger.
62. magnetic core as claimed in claim 59, the blending ratio of wherein said adhesive in described mixture is 1 quality % or still less, molding temperature is positioned at the supercooled liquid scope of described amorphous soft magnetic powder, the activity coefficient of described material powder in described magnetic core be 90% or more than, when applying 1.6 * 10
4During the magnetic field of A/m magnetic density be 0.9T or more than, and resistivity is 0.01 Ω cm or bigger.
63. magnetic core as claimed in claim 59, wherein said material powder contain the soft-magnetic alloy powder of 5 volume % to 50 volume %, compare with described amorphous soft magnetic powder, the medium particle diameter of described soft-magnetic alloy powder is less, and hardness is lower.
64. magnetic core as claimed in claim 54, wherein said magnetic core forms by heat-treating in the temperature range of Curie temperature that is equal to or higher than described amorphous soft magnetic and the crystallization onset temperature that is equal to or less than described amorphous soft magnetic.
65. one kind by using the inductance component that coil with at least one circle forms on magnetic core as claimed in claim 54.
66. one kind by carrying out the Unitarily molded inductance component that forms to magnetic core as claimed in claim 59 and coil, wherein said coil forms by twining at least one astragal shape conductor, and is placed in the described magnetic core.
67. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 49 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 10kHz or above frequency band be 20 or more than.
68. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 50 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 100kHz or above frequency band be 25 or more than.
69. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 51 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 500kHz or above frequency band be 40 or more than.
70. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 52 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 1MHz or above frequency band be 50 or more than.
71. as the described inductance component of claim 67, wherein said coil forms by twining at least one astragal shape conductor, and is placed in the described magnetic core, described magnetic core and described coil are integrally molded.
72. as the described inductance component of claim 65, wherein said magnetic core is formed with breach.
73. as the described magnetic core of claim 65, wherein said magnetic core forms by heat-treating in the temperature range of Curie temperature that is equal to or higher than described amorphous soft magnetic and the crystallization onset temperature that is equal to or less than described amorphous soft magnetic.
74. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 53 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 100kHz or above frequency band be 25 or more than.
75. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 53 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 500kHz or above frequency band be 40 or more than.
76. inductance component, described inductance component is applied on the magnetic core by the coil that will have at least one circle and forms, described magnetic core is by carrying out molded formation to the material powder that comprises amorphous soft magnetic powder as claimed in claim 53 with the mixture that 5 quality % or amount still less are added into adhesive wherein, the activity coefficient of described material powder in described magnetic core be 50% or more than, Q (1/tan δ) peak value of wherein said inductance component in 1MHz or above frequency band be 50 or more than.
77. as the described inductance component of claim 74, wherein said coil forms by twining at least one astragal shape conductor, and is placed in the described magnetic core, described magnetic core and described coil are integrally molded.
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| JP2006026210 | 2006-02-02 | ||
| JP2006026210 | 2006-02-02 | ||
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| CN201410049912.8A Division CN103794327A (en) | 2006-02-02 | 2007-02-02 | Amorphous soft magnetic alloy and inductance component using the same |
| CN2009101276395A Division CN101572154B (en) | 2006-02-02 | 2007-02-02 | Amorphous soft magnetic alloy and inductance component using the same |
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| JPH0845723A (en) * | 1994-08-01 | 1996-02-16 | Hitachi Metals Ltd | Nano-crystalline alloy thin band of excellent insulating property and nano-crystalline alloy magnetic core as well as insulating film forming method of nano-crystalline alloy thin band |
| DE19802349B4 (en) * | 1997-01-23 | 2010-04-15 | Alps Electric Co., Ltd. | Soft magnetic amorphous alloy, high hardness amorphous alloy and their use |
| JP3771224B2 (en) * | 2002-09-11 | 2006-04-26 | アルプス電気株式会社 | Amorphous soft magnetic alloy powder and powder core and radio wave absorber using the same |
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- 2007-02-02 CN CN2009101276395A patent/CN101572154B/en active Active
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Also Published As
| Publication number | Publication date |
|---|---|
| CN101572153B (en) | 2012-10-24 |
| CN101572154A (en) | 2009-11-04 |
| CN101572153A (en) | 2009-11-04 |
| CN101572154B (en) | 2012-10-24 |
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Application publication date: 20070912 |